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1993 Mazda RX-7 Maintenance Information

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1. ESCO Institute 1350 West Northwest Highway Suite 205 Mount Prospect IL 60056 800 726 9696 Approval Date 12 27 94 New York State Department of Motor Vehicles Division of Vehicl Safety Technical Training Unit Empire State Plaza Swan Street Building Room 111 Albany New York 12228 518 474 4049 Approval Date 5 10 95 Air Conditioning Contractors of America Ferris State University 1712 New Hampshire Avenue NW Washington D C 20009 202 483 9370 Approval Date 9 22 95 The programs listed below are intended specifically for the employees of these companies
2. 3 Clardy Manufacturing Co CP4MA 3 C Mar Industries Inc 2 CM20 12A 3 3 DAVECO Recovery Division of 41250 41250 2 3 3 DAVECO Industries Inc 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM j Econozone Inc 3 Econozone 29A 3 3 RSB Engineering 3 3 E Environmental Products 4 EP10A 2 Amalgamated PTY Ltd 2 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1 Environmental 3 The
3. 3 Service Code No 06 Speed Sensor 1 Revolution Sensor 3 AAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Step Inspection 3 Action 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1 Are there any poor Yes Repair or Replace connector 3 3 connections at speed 3 3 3 3 3 sensor 1 and EC AT control AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 unit connectors 3 No Go to next step 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 2 3 Connect a circuit tester 3 Yes Go to Step 5 3 3 to terminals 2J and 2L as 3 3 shown in Fig 3 3 3 3 3 Is input voltage of speed 2 3 sensor 1 at EC AT control AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 unit OK 3 No 3 Go to next step 3 3 Acceptable Voltages 3 3 3 3 Approx above 1 while 3 3 2 driving above 16 mph 2 3 3 3 3 3 Approx 0 Vehicle stopped SUSCI LS 111 3 3 Disconnect 20 pin EC AT 3 Yes Go to Step 5 3 control unit connector 3 3 3 3 Ts resistance between 2J 3 3 3 3 terminal and 2L terminal
4. 3 D 3 12mm 10 8 x 1 78 3 LB54 61 J1X 2 3 3 F 3 16mm 14 0x 1 78 LB56 61 J1X 3 3 AU NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 8 for O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM 1989 MAZDA RX 7 SANDEN bs COMPRESSOR NIPPONDENSO UN J COMPRESSOR 95652015 Fig 8 1989 94 RX 7 O Ring Identification 1995 96 RX 7 O RING DESCRIPTION TABLE A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM
5. 3 D 3 12mm 10 8 x 1 78 3 LB54 61 J1X 7 3 1 F 3 16mm 3 14 0x 1 78 LB56 61 J1X 2 2 U NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 16 for O Ring Identification 1994 95 MPV SINGLE AIR A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 08AM O RING DESCRIPTION TABLE 3 3 3 Quantity Per Vehicle 3 3 3 3 3 3 3 1 3
6. DEO 3 Pipe 3 O Ring s Part Numbers 3 Quantity Ring lt Size 3 Size D X T 3 and 3 Per 7 3 Code 3 3 7 Kit Numbers 3 Vehicle E 3 A x 8mm E 6 9 x 1 78 3 LB51 61 J1X 3 6 3 3 D 3 12mm 10 8 x 1 78 3 LB54 61 J1X 1 3 E 3 12mm 3 10 8 x 2 4 3 LB55 61 J1X 1 3 3 axial 3 3 3 3 3 16mm 3 14 0x 1 78 LB56 61 J1X 2 5
7. U VEHICLE PREPARATION AND CONDITION 1 The vehicle should have No Passengers No Luggage Gas Tank Full Radiator and Engine Oil To The Specified Levels Spare Tire Jack And Tool Stored In Designated Areas Tire Pressure Checked And If Necessary Adjusted NOTE If the specifications are different depending on load conditions adjust the pressure for the lightest load 2 The table below contains examples of front caster specifications based on fuel tank level CASTER EXAMPLE TABLE UAAAKAAAAAAAAAAAAAAAAAAAABAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Fuel Gauge 3 Front Caster 3 Indication Shown in degrees minutes 3 3 Empty 3 3 degrees 05 to 5 degrees 05 3 2 L 4 3 3 degrees 10 to 5 degrees 10 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA L 2 3 3 degrees 15 to 5 degrees 15 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 4 3 3 degrees 20 to 5 degrees 20 3 AA AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Ful
8. ds 10 16 x 1 95 2 ZZLO 61 J19 KIT 3 4 3 KR D78340 1295 1 95 2 ZZLO 61 J19 KIT 3 U NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 19 for O Ring Identification NOTE Ford A C System See Fig 9 for O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 18 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM High Side J Navajo 1991 94 Low Side K ALTER ie lt gt S 1222 aw iz br P s e Kx an lt amp HQE i E I3 AS T N f LR SJ LSE inim 5 ja 1 ss 2 3 d S3 Ss 3 ES oi m X n d n tg b di w Der LS gt Ra NN x f w gt y L D TW
9. 1 3 At cold temperatures or high 2 HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM 3 humidity the windows never clear 3 3 all 3 3 ARAAAAAAAARAAAARARAARAAAARARAAAAAAAARAARARARAARAAAAAAAAAAAAAAARAAAAAAA 2 3 Even after reaching normal E 3 operating temp the front wind 5 7 3 shield is only cleared 30 50 5 3 I 3 3 Rear window does not clear 3 4 3 Rear window clears only in the 3 3 middle 3 3 Temperature Control Concern
10. U NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 14 for O Ring Identification 2 c 95H51943 Fig 14 1989 93 MPV Dual Air O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM EEO EN ER x 3 Pipe O Ring 3 Part Numbers 3 Quantity 3 Ring 3 Size 3 Size D X T 3 and 3 Per E 3 Code 3 3 I Kit Numbers 3 Vehicle 7 B 5 1610 3 6 8 x 1 5 3 LB52 61 JIX 3 13 2 3 D 3 12mm 10 8 x 1 78 3 LB54 61 J1X 3 3 2
11. U NOTE Although the part has been modified the part number is the same WARRANTY INFORMATION Applies To vehicles covered under warranty Warranty Type Code A Customer Comment Code 82 Damage Code 97 Part No of Main Cause 39 040C Operation No CO601ARX Labor Hours 3 2 Hrs END OF ARTICLE CALIFORNIA REFORMULATED GASOLINE CAT F NO 014 96 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN CALIFORNIA REFORMULATED GASOLINE Model 5 All Mazda Models Category F Fuel amp Emission Control Systems Bulletin No 014 96 Date June 6 1996 DESCRIPTION This bulletin is issued to provide service personnel with information to answer commonly asked questions regarding California Reformulated Gasoline CaRFG Please use this information to address customer concerns BACKGROUND The purpose of CaRFG is to reduce emissions CaRFG replaces the traditionally high pollution generating gasoline distributed in Northern California CaRFG improves the reformulated gasoline distributed in Southern California The California Air Reso
12. 3 Brakes 3 CMH CMH 3 CMH 3 CMH 3 CMH 3 Park pawl CMH 3 CMH 3 CMH 3 CMH 3 CMH 3 Int linkage CMH 3 CMH 3 CMH 3 CMH 3 CMH 3 z Hydraulic governot En 30 pee Me Soe M 3 Servo pistons CMH 3 CMH 3 CMH 3 CMH 3 CMH 3 2 Differential 2 Ee 3 CMH 3 CMH 3 CMH
13. 3o ru 3 16mm 3 14 0x 1 78 3 LB56 61 J1X 1 3 x U NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 7 for O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM 626 MX 6 1993 96 95B51947 Fig 7 1993 96 626 MX 6 O Ring Identification 1989 94 RX 7 O RING DESCRIPTION TABLE o 3 Pipe 3 O Ring 3 Part Numbers 3 Quantity 3 Ring 3 Size 3 Size D X T 3 and 3 Per 1 3 Code 3 3 7 Kit Numbers 3 Vehicle 3 A 3 8mm 3 6 9 x T 78 2 LB51 61 J1X 3 6 2
14. 31994 B TRUCKS i NONE 7 3 2 U De 5 Year Model Engine P N 3 Gasket P N 3 Remarks 31989 94 MPV 2 6L G6Y5 02 300 3 8AL1 02 310 3 3 1989 94 MPV 4X2 JE57 02 300 3 8AL2 02 310 3 3 3 0L 4X4 JE58 02 300 7 8AL2 02 310 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU RS Rd al d da a cleat ale U
15. Geneva Steel P O Box 2500 Provo Utah 84603 801 227 9000 Approval Date 2 4 93 Jiffy Lube International P O Box 2967 Houston Texas 77252 2967 713 546 4100 Approval Date 9 14 93 Kmart Corporation East Central Regional Office Auto Training Center 551 North Hicks Road Palatine Illinois 60067 708 358 3205 Approval Date 8 12 92 Los Angeles County Metropolitan Transportation Authority MTA 900 Lyon Street Los Angeles California 90012 213 972 5159 HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 16 1993 Mazda RX7 For www iluvmy
16. P Mazda SPX Robinair 3 L7401MAZ S AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 MDI 1 2 HPCA 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Mitsubishi SPX Robinair 3 17400MIT 17401MIT 3 7 Moog Automotive Inc 3 209990 Murray Corporation ATC 1000 1100 5000 3 Myers Enterprises 3 MR 1991 A MR 1991 R ME 1991 A 3 NAPA 3 209990 3
17. 3 Internal Components NA4A HL LA4A EL A4LD 35 4R44E 3 3 3 3 3 3 AR55E 3 Oil Pump s CMH CMH CMH 3 CMH 3 AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Clutches 3 CMH 3 CMH 3 CMH 3 CMH 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Pistons 3 CMH 3 CMH 3 CMH 3 CMH 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Gears i CMH 3 CMH 3 CMH 3 CMH 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Shafts 3 CMH 3 CMH 3 CMH 3 CMH 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Bearings CMH CMH 3 CMH 3 CMH ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 Seal Rings CMH 3 CMH 26 CMH 3 5 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 O rings CMH 3 CMH 3 CMH 3 CMH 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Bands 3 CMH 3 CMH 3 CMH 3 CMH 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
18. 3 Walsco Components Inc 3 WC 2 3 3 White Industries 3 01050 01060 01061 01080 01095 3 3 Division of K Whit Tools 01075 01234a 3 Wynn s Climate Systems 3 90 0001A 0458A 1100A 3 3 1300A 1500A 3 The Youngstown Research 3 RRR SS BH RRR x 3 and Development Company 3 i YRD formerly x 3 International Carbonics 3 3 Dual refrigerant 7 3 Multiple listing 3 Certified by ETL Inc 2
19. 3 Rear window ON 3 OFF 3 3 3 defroster 3 3 AKA 3 3 switch 3 7 3 3 A C switch 3 ON OFF 3 Blower switch at 1st 3 7 3 3 or higher position U PAGE F 137 THROTTLE ILLUSTRATION CORRECTION The illustration on page F 137 contains an illustration that has been revised Fig 3 contains the revised illustration EXgi 32 WORKSHOP MANUAL CORRECTION FUEL SYSTEM CAT W NO 040 92 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 40AM ACTUATOR DOUBLE THROTTLE CONTROL CHECK VALVE SECONDARY PRIMARY SOLENOID VALVE DOUBLE THROTTLE CONTROL IDLE ZONE VALVE OPEN COOLANT TEMPERATURE ABOVE 80 C 176 F VALVE CLOSED COOLANT TEMPERATURE ABOVE 80 C 176 F 94F55496 Solenoid Valve Logic Circuit PAGE F 158 TERMINAL 3D TEST CONDITION CORRECTION Page F
20. 3 Applied Ecological I 2 2 3 Systems 3 3 2 Assemblies Systems 3 NS 2000 3 Corp 3 3 3 Atlas Supply Company 3 EAC 205 250 750 3 1400 1500 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Atlas SPX 3 EAC 125 EAC 370 679125 679137 HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM 2 Robinair 3 3 3 Automotive Diagnostics 3 40 375 3 3 Division of 3 3 2 SPX Corporation 3 3
21. degrees 3 3 3 left 3 3 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Toe Total toe in 4mm Angle 3 One side toe is 3 3 indicated is also not mentioned 3 3 3 described 3 No specification ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA ALIGNMENT SPECIFICATIONS AND TOLERANCES INFORMATION CAT N NO 001 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 22AM 3 Rear 7 Camber Difference 7 1 1 5 degrees 3 3 between right and 3 3 3 left 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 Toe Total toe in ff 4mm Angle 5 One side toe is 3 3 3 3 3 3 indicated is also not mentioned 3 3 described 3 No specification 3 Thrust Angle 3 0 8 degrees 3 3 AAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAA 3 NOTE Each vehicle varies in specification median Refer to the 3 appropriate service information for each vehicle s 3 3 specification 3
22. 3 Part Number 07 ARAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 9 inch 3 12 inch 3 VIN 3 Seat Position 3 LBY4 57 63X 3 LBY5 57 63X 3 All 7 2nd amp 3rd Seat 3 3 3 3 3 Position 3 AAAAAKAKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU END OF ARTICLE SQUEAKING NOISE WHEN OPENING CLOSING DOOR CHECKER CAT S NO 010 94 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 41AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SQUEAKING NOISE WHEN OPENING OR CLOSING DOOR Model 5 1993 Mazda RX 7 VIN of JM1FD33 P0200001 through JMIFD33 P0210664 Category S Bulletin No 010 94 Date 2 11 94 SERVICE INFORMATION NOTE The asterisk in the VIN range can be any number 0 through 9 or X DESCRIPTION When opening or closing the door a squeaking sound may be heard This is caused by the door checker To correct this problem the checker has been modified Follow the procedures listed in section S of the workshop manual to replace the door checker for customers complaining of this noise Replace Checker NC 94A52449 Fig 1
23. 1 3 Difficult to set temperature 3 3 2 3 Temperature unbalance between 3 3 3 head and foot 3 3 Temperature unbalance between 4 3 3 driver and passenger seat 3 4 Other Concerns ab 3 3 3 2 3 3 3
24. 8 Model 3 Battery 3 Max Charge Charge Time Load Test 3 3 3 3 Current AMP 3 Min 3 AMP 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Protege 323 3 55D23L 3 30 3 30 s L80 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 626 MX 6 3 GROUP58R 30 3 30 L74 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 929 55D23L 2 30 3 30 2 180 3 3 80D26L 3 35 30 3 L95 AAARAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Millenia 3 75D26L 3 35 3 30 3 195 x 3 3 80D26L 3 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 MX 3 3 50D20L 3 25 3 30 150 3 3 3 55D23L 3 30 3 30 3 180 65D23L 3 30 30 3 L65 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAARARARAAAAAA 3 MX 5 Miata S46A24L 3 20 3 30 LOS AAAARARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 RX 7 3 55D23L 3 30 3 30 3 180 3 65D23L 3 30 3 30 3 165 3 i 75D26L 3 35 3 30 L95 s AAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 MPV 50D20L 5 25 3 30 2 150 3 3 80D26L 3 35 3 30 3 195 2 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 B Series 3 50D20L 3 25 3 30 3 150 gt 2 3 75D26L 3 35 I 30 2 195 2
25. U 9 If the value of fuel pressur Max is below standard measure the voltage at the fuel pump connector vehicle side using the procedures below A Reinstall the jumper wire and turn the Ignition on Refer to steps 6 and 7 of the previous page B Connect test leads to the fuel pump positive and negative terminals and measure the voltage at the fuel pump connector vehicle side S Fig 8 for illustration ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM 94C53035 Fig 8 Measuring Fuel Pump Voltage NOTE Do not disconnect the fuel pump connector If the voltage is above the standard value replace the fuel pump f the voltage is below standard check for a damaged harness relay or a poor ground at the pump Standard Value 8 5V and over 93 RX 7 9 5V and over Other Models After restoring the standard voltage value measure the fuel pump kiz pressure Max If pressure is not to specification replace the fuel pump If no trouble is found with the fuel pump and the problem still exists contact the Technical Hotline for assistance
26. CUSTOMER COMMENT SHEET Please complete the following with the aid of the customer 1 Heater Concern No 3 Customer Comment 3 Checked 3 Result 1 3 Water temp indicator reads low at 3 E 3 high speed s i 2 3 While driving the interior temp 3 3 is cooler than when parked 3 3 3 Heater outlet air temperature is 3 3 3 always cold 3 3
27. 3 1977 80 3 GLC RWD 320 0000 80 0024 WB 460 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 1992 95 3 All 1 6L 35 310 0000 80 026R WB 525 3 3 3 MX 3 3 1992 95 3 Optional For Above 360 0000 80 0035 WB 550 3 3 3 1992 95 3 All V 6 1 8L 35 415 3 0000 80 024F WB 525 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 3 3 3 3 ww ww 1993 97 3 All 3 582 0000 80 058R WB 582 3 626 MX 6 3 1983 92 All Except Diesel 7 320 0000 80 026R WB 525 3 3 1983 92 Optional For Above 360 0000 80 0035 WB 550 3
28. Cooling fan shuts off 3 Memory needs cleared when the key is turned Disconnect the battery and start off during the fan 2 fan test over test 2 w w w gt 3 3 3 3 Cooling fan comes on 3 If the vehicle was produced before A 3 3 immediately when the April 1 1993 VIN of JMIFD331 3 key is turned on and P0210660 or less 3 3 3 3 3 3 3 3 3 the check connector is The fan should come on immediately 3 grounded when the key is turned on 3 3 3 3 3 ave the key on and the fan perating for at least 150 seconds L Turn the key off and proceed with jE 3 3 3 3 3 3 3 3 he test AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Fan operates only on 3 Check that the harnesses with the 3 3 medium speed during fan 3 Black wires are connected 3 3 test 3 NOTE The other two 2 harnesses are interchangeable ARAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU COMPONENT TROUBLESHOOTING AND INSPECTION PROCEDURE 1 Perform Spark Plug and Ignition Coil Inspectio
29. RC ZX99A 0000 1 0000 1 8 097B 8 098A 8 098A 8 099A 8 099A 0000 8 00A 1987 93 1988 89 1988 91 1989 94 B2600 RC ME 323 Turbo 3 RC ZE 929 Except S 3 RC ZE MPV 3 01 s RC ZE E51 3 0000 8 101A E07 3 0000 8 102A E06 3 0000
30. U 3 YES 3 Return To Customer 3 AAAAAAAAAAAAAAAAAAAAAU PART 2 OF FLOW CHART UAAAAAAAAAAAAAAAAAA PRE CHECK PROCEDURES Is A T Fluid In 3 Review Repair History 3 Good Condition 3 Check Engine Electrical System Performance 3 YES Check For Non Factory Equipment 3 Perform Pre Checks amp Retrieve Check Shift Linkage Adjustment 3 Codes Using The NGS Tester 4 Vehicles With Ford Components U KOEO and KOER Tests NO 3 Codes AAAAAAAAAAAAAAAAAAAAAAAAAAKAAAA 3 YES 5 3 3 Repair Vehicle Per Self Diagnostic 3 3 Function And Clear Code From Memory 2 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAU 3 UAAAAAAAAAAAAAAAAAAAAAAY NO 3 3 Is Vehicle Repaired AAAAAAAAAAAAAAAAAAAAAAKA AAAAAAAAAAAAAAAAAAAAAAAU 3 3 YES 3 3 3 Return To Customer 3 3 AAAAAAAAAAA
31. AU NOTE Fig 16 Part numbers ending in J1X are delivered in quantities of for O Ring Identification See Fig 16 1989 95 MPV Single Air E 1994 95 D 1989 93 O Ring Identification 1990 93 B SERIES O RING DESCRIPTION TABLE E 10 G 1994 95 F 1989 93 A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 16 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM DEO 3 Pipe 3 O Ring s Part Numbers 3 Quantity Ring lt Size 3 Size D X T 3 and 3 Per 7 3 Code 3 2 3 Kit Numbers 3 Vehicle E 3 3 8in 7 7 65 x 1 78 3 L853 61 JIX E 4 z D 12mn 10 8 x 1 78
32. 3 MX 6 626 3 1993 and prior 3 R12 3 ATMOS S150 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 3 1994 and after 3 R134a 3 ATMOS GU10 3 3 Protege 1994 and prior 3 R12 3 ATMOS S150 3 3 3 1995 and after 3 R134a 3 SP10 3 Miata 3 1993 and prior 3 R12 2 ND7 3 3 1994 and after 3 R134a 3 ND9 3 RX 7 3 1994 and prior 3 R12 7 7 3
33. 3 X 3 1995 96 MILLENIA 3 O 4 3 O 3 0 5 3 O O 3 AAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Ke 3 L996 PROTEGE MT 3 O 4 3 3 O 3 ir O 3 A ARARARAARARARARARARAAAARARARARARAAAARARARAAARAAAAAARARARAAAAAA E ax 1996 PROTEGE AT 3 O 4 3 O 3 O 3 cire 78 O 3 AAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 X 3 1996 626 MX 6 MT 3 O 4 3 3 O 3 ec O 3 AAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAA AAA AT 3 O 4 3 O 3 O 3 en 23 O 3 AAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA MT 3 O 4 3 ete 3 3 O 3 AKAAAAARARAAAARAAAAARAAAAAARAAAAAAARAAAARAAAAAAARAAAARAAAAARARAR AT 3 O 4 3 E o 3 O 3 O 3 RAARARARAARARARARARARAAAARARARARARAAAARARARANARAAAAAARARARARAAAAA 3 O 4 3 O 3 O 3 3 O 3 AAKAAAAAAAAAARAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAABAAAAAAAAA B3000 3 X 3 1996 626 MX 6 1996 MIATA a Ux 3 1996 MIATA DE AK 1996 MPV 3 X 3 1996 B2300 I B4000 MT 3 3 O 4 3 3 3 A Em 3 ciem 3 O 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4996 z B4000 B2300 B3000 AT 3 3 O 4 3 3 3 3 3 O 3 O 3 3 ee
34. 3 1984 85 3 Diesel 3 620 3 0000 80 124F WB 700 3 MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 w 3 1979 82 3 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM All 3 235 0000 80 0024 WB 460 3 AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1993 95 3 M T 3 420 0000 80 026R WB 525 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA RX 7 3 1984 92 A 3 3 3 3 3 1979 83 3 Al 3 320 0000 80 026R WB 525 3 ARARARARARARARARARARAARARARARARARARARARARARARARAARARARARARARA 3 370 0000 80 0024 WB 460 AARAAARAAAAARARAAAAAARARARARAARARARAARARAAAARAAARARAAARARAAARARAAAARAC 3 3237 3 1988 97 3 A 3 310 0000 80 026R WB 525 ProtegeAAAARARAARARAAAARARAARARAAAARARAARARARAARAAAARARAAAAAAAAARAR 1988 97 3 Optional For Above
35. 3 3 3 3 Record in the appropriate column if the item was checked and the result 1 Heater Concern Use the Diagnostic Flow Chart see Fig 2 to determine the necessary diagnostic checks Refer to the Check Sheet Fig HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Diagnostic Flow Chart 1 Heater Concern 2 Defroster Concern Refer to Check Sheet item 1 70 degrees C 65 degrees c or higher or lower Refer to Check Sheet Refer to Check Sheet item 2 item 3 Completed Front window does not clear Refer to Check Sheet item 3 Perform necessary repairs Completed OK N G Refer to Check Sheet Perform repairs as item 4 step 1 necessary Recheck Check Sheet Recheck Check Sheet item 1
36. 3 A 5 8mm 9 9 3 Tl 78 9 LB51 61 J1X 3 4 2 3 D 3 12mm 10 8 x 1 78 3 LB54 61 J1X 3 3 3 NES 3 16mm 3 14 0x 1 78 3 LB56 61 J1X 3 3 A AAAAAAA AAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAU NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 4 for O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM 95451960 Fig 4 1990 93 MX 5 O Ring Identification 1994 96 MX 5 O RING DESCRIPTION TABLE Pipe 4 O Ring 3 Part Numbers 3 Quantity Ring 3 Size 3 Size
37. 3 1990 93 3 B2200 3 3 3 3 3 3 3 CAL ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A FED 8AU1 02 310 3 3 FEY3 02 300 3 3 3 3 3 3 3 3 F2Y3 02 300 8AU2 02 310 F2Y6 02 300 8AU5 02 310 F2Y7 02 300 gt 8AU2 02 310 Requires th E replacement of the Heat SOME Unit G607 18 510 3 3 3 3 PARTIAL ENGINE LONG BLOCK AVAILABILITY CAT B NO 004 94 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 36AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1990 93 B2600 A T G6Y1 02 300 7 8AU3 02 310 3 4x4 A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 M T G6Y2 02 300 8AU3 02 310 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 31990 93 B2600 A T G6Y3 02 300 7 8AU3 02 310 3 4x2 A MAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 M T G6Y4 02 300 7 8AU3 02 310 3
38. RC ZX4 3 1 0000 8 141A 3 E30 0000 8 130A E31 3 0000 8 131A E35 3 0000 8 135A E36 3 0000 8 136A E36 0000 E37 3 0000 8 137A SPARK PLUG CROSS REFERENCE CHART NO T 1 3 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 01AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SPARK PLUG CROSS REFERENCE CHART Model All Mazda Date November 1 1990 Revised April 27 1992 No Group Parts SPA
39. WARRANTY INFORMATION Applies to verified customer complaints on vehicles covered under normal warranty Refer to the SRT microfiche for warranty Term Information Warranty Type A Symptom Code 08 Damage Code 9S Part Number Main Cause FD02 67 E70 Quantity 1 Operation Number XX899XRX Labor Hours 0 2 hrs END OF ARTICLE INSPECTION PROCEDURE FOR TEST LEAD OF NGS TESTER CAT ST NO 006 98 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 35PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN INSPECTION PROCEDURE FOR TEST LEAD OF NGS TESTER Model 5 All Mazda Models Category ST Service Tool Bulletin No 006 98 Date September 30 1998 DESCRIPTION The NGS test lead connectors may become loose or corroded causing incorrect readings Before using the ohm meter function of the NGS tester for diagnosing electrical circuits check for excessive resistance in the test leads and connectors and repair them if necessary NOTE Two types of connectors screw and solder are used on the NGS test leads TEST LEAD AUX SIG RED GREEN 98E54134 Fig 1 NGS Tester INSPECTION PROCEDURE 1 Verify concern INSPECTION PROCEDURE FOR TEST LEAD OF NGS TESTER CAT ST NO 006
40. 3 Replacement N3A1 13 S70 3 N3A1 13 S70 3 N3A1 13 S70 3 3 Part No 3 3 AR AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 N3Z1 15 S10B N3Z1 15 S10B 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 N3A1 13 S60 3 N3A1 13 S60 3 I 3 3 N3C1 15 173 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 N3Z 5 S20 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 All Quantities All Quantities All Quantities 3 3 are 1 3 are 1 are 1 END ARTICLE
41. 3 3 3 3 Environmental SKYE EP3 SKYE EP 4 5 3 Products 5 Amalgamated 3 3 Pty Ltd 3 3 3 Environrnental 3 FICS 9000 3 Systems Products 3 3 3 Inc 3 3 HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 3 Enviroronmental 3 SYSTEM I 102 12 3 Technologies 3 3 3 Corporation 3 2 3 Everco SPX Robinair 3 A9990 3 3 Everco Industries Inc 3 A9950 3 3 Firestone SPX Robinair 7 TE 48 30 960 7 3
42. 3 Cable Condition 2 Must be free of corrosion 3 1 3 terminals tight 2 P Vehicle Wiring Grounds 3 Check by voltage drop measurements ARAAAAAAAARAAAARARAARARAAAAAAAARAAAARAAAAAARAAAAAAAAAARAARAAAARAAAAC Alternator 3 Check alternator output between 3 3 13 5 and 15 5 volts 3 MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM 3 Alternator Drive Belt 3 Must be set to correct tension and 7 E 3 in good condition AAAAAAARAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAU A preliminary check of these items will in most cases reveal th problem without time consuming detailed diagnostics NOTE As a result of product testing on returned parts 60 of the returned alternators and 20 of returned batteries are classified NTF No Trouble Found BATTERY MAINTENANCE RESPONSIBILITY Mazda Moto
43. Service Code No 57 Reduce Torque Signal Torque Reduced Signal AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Step Inspection Action 3 1 Are there any poor 3 Yes Repair or Replace connector 3 3 3 connections at engine 3 3 3 control unit and EC AT AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 control unit connectors 3 No 3 Go to next step 3 2 Connect a circuit tester 3 Yes Go to Step 4 3 3 3 to terminals 2H and ground 3 3 3 E 3 as shown in Fig 8 2 3 3 Is input voltage of torque I 3 reduced signal at EC AT AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 control unit OK 3 No 3 Go to next step 3 Acceptable Voltages 1 2 3 2 3 Battery voltage Engine 3 I 3 3 idling 3 3 3 3 Below volt Engine cool 3 3 ARAAAAAAAARAAAAAAARARAAAARAAAARAAAAAAAARAAAAAAAAAAAAAAAARARAARARAA
44. See Fig 1 SPARK PLUG CROSS REFERENCE CHART NO T 1 3 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 01AM N342 18 110 N343 18 110 Leading SD10A Trailing SDIIA Spark Plug Carton Trailing Upper Part Number Leading Lower Leet 93B51764 Fig 1 Spark Plug Identification for 1986 91 RX 7 Engines END OF ARTICLE TAS THROTTLE ADJUSTMENT SCREW LOCATION ADJUSTMENT CAT F NO 014 98 ARTICLE BEGINNING Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 01AM TECHNICAL SERVICE BULLETIN TAS THROTTLE ADJUSTMENT SCREW ADJUSTMENT Model 5 All Mazda Models with Fuel Injection Category F 01 Fuel amp Emission Control Bulletin No 014 98 Date December 9 1998 VEHICLES AFFECTED All fuel injected models DESCRIPTION Fuel injected vehicles with idle speed control motors should NOT have the TAS Throttle Adjustment Screw adjusted for any reason The TAS functions as a stopper when the throttle valve is fully closed During production the TAS is accurately set by measuring the airflow rate past a closed throttle plate Any adjustment to this screw wi
45. 1 Was the customer s complaint verified Yes No 2 Battery Inspection Results AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Information Reading 3 3 Instrument Used For Test 3 3 Battery Voltage Open Terminal Volts 3 3 Battery Voltage Load Test 3 Volts 3 U Authorization Number if battery was replaced prior to retail sale or within 90 days of retail sale Vehicle Year Model VIN Mileage Repair Date R O Number Technician Number These check sheets are available through HELM Inc free of charge MN A rv D AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA BATTERY TAG MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 12 1993 Mazda RX
46. 3 F 3 16mm 14 0x 1 78 LB56 61 J1X 3 9 AU NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 15 for O Ring Identification MPV DUAL 1994 95 95151944 Fig 15 1994 95 MPV Dual Air O Ring Identification Cu PU LM SC M Ir MC D 5 3 Pipe O Ring Part Numbers 3 Quantity gt Rang Size 3 Size DXT 3 and 3 Per 3 3 Code 3 3 3 Kit Numbers 3 Vehicle 3 3 B 37 DZ 1635 9 6 8 x 1 5 3 LB52 61 J1X 2 3 1 s n Ses 8 1462 1 478 3 L853 61 J1X 3 1 3
47. t SH 3 3 8in 7 36 x 1 80 ZZLO 61 J19 KIT 2 3 Po 3 16 oa 85 9 ZZLO 61 J19 KIT 3 2 3 2K 5 8ane 2 95 3 1 95 ZZLO 61 J19 KIT 3 2 E AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 10 for O Ring Identification 929 1992 93 95F51941 Fig 10 1992 93 929 O Ring Identification 1994 95 929 O RING DESCRIPTION TABLE wa 3 Pipe O Ring 3 Part Numbers 3 Quantity Ring 3 Size 3 Size D X T 3 and Per r 3 Code 3 3 I Kit Numbers 3 Vehicle 7
48. 2 Connect a circuit tester 3 Yes Go to Step 5 to terminals 1G and ground as shown in Fig 2 Is 3 No 3 Go to next step input voltage of engin 3 3 RPM signal at EC AT control unit OK Acceptable Voltages 0 volts engine stopped w w w w w UQ www 3 3 3 3 3 3 3 3 3 8 volts engine idling 1 8 2 2 volts engine 3 running at 3 000 rpm i with no load ARAAAAAAAAAAAAAAAARARAAAARAAAARAAAAAAAARAAAAAAAAAAAAAAAARARAARARAAAAA 3 3 Disconnect 16 pin EC AT 3 Yes Go to next step 3 control unit connector 3 3 3 Is there continuity between 3 3 3 3 1G terminal of EC AT 3 3 3 3 control unit and 2B AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 terminal of engine control No Repair wiring 2 3 3 unit 3 3 3 3 4 3 Connect a circuit tester 3 Yes Go to next step 3 3 3 to terminals 2B and ground A A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 as shown in Fig 2 Is 3 No Check c
49. 3 2 3 Accumulator DUM EN CM NE URS 3 T C Housing 4 3 CMH 3 CMH 3 CMH 3 CMH 3 CMH 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Main case 4 3 CMH 3 CMH CMH 3 CMH 3 CMH 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAA AAAAAAAA AAAAAAA AAAAAAA 3 ADJ Adjust as needed per W M authorization not required 3 RPL Repair or replace as needed per W M authorization not 3 required 3 3 CMH Call MASH Hotline for REMAN ASSEMBLY authorization do 3 not repair or replace component 3 3 1 Throttle cable not used on GF4A EL 3 2 Do not replace converter if oil pan is full of debris 3 CALL MASH HOTLINE 3 3 3 2 3 accumulator is internal and not serviceable CALL 3 MASH HOTLINE 3 3 4 If cracked porous leakage damaged other CALL 3 MASH HOTLINE U MAZDA AUTOMATIC TRANSMISSION APPLICATION TABLE 6 OF 6
50. END OF ARTICLE NOISE WHEN OPERATING POWER WINDOWS NEW STOPPER CAT S NO 031 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN POWER WINDOW OPERATION NOISE Model 5 1993 Mazda RX 7 with a VIN of JM1FD33 P0200001 through JM1FD33 P0210508 Category S Body Bulletin No 031 93 Date 6 16 93 DESCRIPTION A bumping noise may be heard inside the door panel when the power window is fully opened A rubber stopper at the bottom of the window regulator has been modified to prevent this noise REPAIR PROCEDURE If this bumping noise is heard replace the rubber stopper with a de modified stopper Rubber Stopper un 74 Window Regulator Rubber Stopper Installation Flange 94D53150 Fig 1 Window Rubber Stopper PARTS INFORMATION TABLE Part Number Description Qty 7 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 FD01 58 565 3 Stopper Rubber 1 3 U WARRA
51. 3 1995 and after 3 R134a ND9 3 2 MX 3 3 1993 and prior 3 R12 3 ATMOS 5150 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 1994 and after 3 R134a 3 ATMOS GU10 3 MPV 3 1993 and prior 3 R12 ND6 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 1994 and after 3 R134a 3 8 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Millenia 3 1995 and after 3 R134a 3 ATMOS GU10 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA i 929 3 1993 and prior 3 R12 3 ATMOS 150 3 USE OF A C TRACER DYE SERVICE INFO CAT U NO 008 97 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 10AM 3 peer eunenereayy 994 and after Ri34a_ 7 ATMOS GUIO AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
52. 3 Base Resistance 3 E2 VC 3 3 3 3 3 3 3 3 U Measure Plate Does Not Move Smoothly YES NO According to Service Bulletin instructions Category No ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM According to DSM or Hot Line Authorization Authorization Other Technician s Signature Date NOTE Attach the check sheet to the repair order If requested to return the failed air flow meter to Mazda attach a copy of the check sheet and repair order FUEL PUMP OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER UAAAAAAAAAAAAAG Diagnostics i iD AA AARRAARRRAARAAU MMA 3 UARARARARAAAAA UAAAAAAAAAAAAAAAAY 3 Results AA No Trouble A Contact Region AAA Found 3 Hot Line 3 3 3 Trouble Found 3 3 3 3 3 AAAAAAAAAAAAAAAA 7 3 Complete 3 3 Hot Line a 3 Check Sheet AAAAAAAA
53. NOTE of 10 6 See Fig Part numbers ending in J1X are de for O Ring Identi livered in quantities ication A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM ee 626 MX 6 1988 92 95A51946 Fig 6 1988 92 626 MX 6 O Ring Identification S un D X Pipe O Ring 3 Part Numbers 3 Quantity Ring 3 Size 3 Size DX T 3 and 3 Per 2 3 Code 3 2 2 Kit Numbers 3 Vehicle q 3 A 8mm 2 69 gel ered ota LB51 61 J1X 3 5 3 12mm 10 8 x 1 78 3 LB54 61 J1X 3 2 3
54. 1990 92 323 1 6L 4x2 B6AL 02 300 7 8AB9 02 310 3 3 AARARARAARARARARKARAARAAAAAAARARAAARAAAAARAARARARAAAAAAAAARARARAAARAA 31993 94 323 FED B6AL 02 300 7 8AB9 02 310 3 3 3 1 6L 4X2 3 CAL B6BN 02 300 7 8AB8 02 310 9 U na A Se D dm bode ns es U PARTIAL ENGINE LONG BLOCK AVAILABILITY CAT B NO 004 94 3 Year Model Article Text 1993 Mazda p 3 RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 36AM 3 3 Engine P N Gasket P N 3 3 Remarks ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1990 94 PROTEGE 3 1 8L DOHC 3 3 1990 94 PROTEGE 3 1 8L SOHC M T A T M T 3
55. U 3 Replace Fuel and 3 3 3 Coolant Hoses 3 3 U 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAA E 3 Follow Repair Procedure 2 3 3 B D AE 3 AAAAAAAAAAAAAAAAYESAAAA Replace Fuel and Coolant 3 3 Hoses and Water Pump 3 U FUEL HOSES REPLACEMENT PROCEDURES PRE CAUTIONS 1 Boost tubes water hoses and fuel hoses should be removed and replaced on the designated side only as shown in the procedure do not remove any joint other than those indicated 2 Do not remove any fuel hose during the check for fuel leakage after replacement please s step 33 RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM If a hose s is removed mistakenly replace the clip s and the hose s with new one s 3 Be sure to use the hoses clips and gaskets designated in this procedure and do not reuse the removed parts 4 When installing the hoses be sure to check their locations in accordance with the instruction and install them correctly PROCEDURE A REPLACEMENT OF FUEL HOSE KIT To be performed on ALL customer sold vehic
56. 3 D 12mm 10 8 x 1 78 3 LB54 61 J1X 3 3 3 5 16mm 3 14 0 T 8 LB56 61 J1X 3 2 3 U NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 3 for O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM MX 3 1992 96 95D51956 Fig 3 1992 96 MX 3 O Ring Identification 1990 93 MX 5 O RING DESCRIPTION TABLE 5 o 3 Pipe O Ring 3 Part Numbers 1 Quantity 3 Ring Size Size DXT 3 and 3 per 1 3 Code 3 3 7 Kit Numbers 3 Vehicle
57. 3 Aprox Battery Minimum Voltage 3 Temperature 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA TOF 210 9 6V i 60F 15C 3 9 5V AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA k 50F 10C 3 9 4V 3 3 40F 4C gt 9 3V 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 30F 1C 3 9 1V 3 AAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAA 3 20F 7C 5 8 9 U If the voltage measures at or above the minimum proceed to step 5 If the voltage is below the minimum quick charge the battery for 30 minutes and load test If the battery remains below the minimum replace the battery and proceed to step 5 NOTE Battery inspection and charging procedures for Navajo vehicles are different than those outlined in this bulletin Refer to the appropriate service information for instructions 5 Start the vehicle and raise the RPM to 2500 6 Connect a battery load tester VAT 40 70 or equivalent 7 Apply a load equal to the alternator rating The generated voltage should be 14 1V to 14 7V LOAD TEST RESULTS Over 14 7V Replace Alternato
58. U NO UAAAAAAAAAAAAAAAAAAAAAAAAA 3 Does vehicle have any AAANOAA Follow Repair Procedure 3 Coolant Leakage 2 B C amp E 3 U 3 Replace Fuel and 3 3 3 Coolant Hoses 3 3 U 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAA E 3 Follow Repair Procedure 2 3 3 B D AE 3 AAAAAAAAAAAAAAAAYESAAAA Replace Fuel and Coolant 3 3 Hoses and Water Pump 3 U FUEL HOSES REPLACEMENT PROCEDURES PRE CAUTIONS 1 Boost tubes water hoses and fuel hoses should be removed and replaced on the designated side only as shown in the procedure do not remove any joint other than those indicated 2 Do not remove any fuel hose during the check for fuel leakage after replacement please s step 33 RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM If a hose s is removed mistakenly replace the clip s and the hose s with new one s 3 Be su
59. 3 Bear SPX Robinair 3 40 310 17352C 17352 3 3 17355C 40 327 40 370 3 P Belco Controls Inc 08 E Carquest Corporation 3 209990 3 Carrier 3 12RA001100 3 3 Caterpillar Inc 3 4C8754 4C8755 905786 3 3 SPX Robinair 3 905787 905788 905789 905790 3 Century Mfg Co 3 MR 1991 A R ME 1991 A 160 002 7 003 004 005 013 014 0T15 3 3 016 Solar 5090 5100 5110 3 3 7100 8100 85100
60. Pan 3 AZ 5 10 16 x 1 85 2 ZZLO 61 J19 KIT 3 4 3 A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM NONU LL NM UR RN UE AP ie aad A AAAAAAAAAAAAAAAARARARAAARARAAAAAAAAAAAAAAAAAAAAAAAAAAARARARAAAAAAAAAAU NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 18 for O Ring Identification NOTE Ford A C System See Fig 18 for O Ring Identification B Series 1994 96 J J Fig 18 1994 96 B Series O Ring Identification 1991 94 NAVAJO O RING DESCRIPTION TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Pipe O Ring 3 Part Numbers 3 Quantity 3 Ring 3 Size size DXT 3 and 3 Per s 3 Code 3 2 2 Kit Numbers 3 Vehicle 7 2 o H Sein 36x 1290 ZZLO 61 J19 KIT 3 3 3
61. 4 3 Passenger side is cooler than 1 3 3 driver s side 2 3 5 3 Passenger feels cold air at feet 3 2 6 3 After vehicle interior has 3 3 reached normal temperature cool 2 3 3 air is felt at body 3 7 3 Upper body is cooler than foot 3 3 8 3 Temperature is unbalanced between 3 3 driver s and passenger s side 3 2 Defroster Concern
62. 3 No 6 to next step 3 3 ww ww www Ut uq www www www 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Yes 3 Check wiring and connectors from EC AT control unit to 3 ATF thermosensor 3 If OK go to next step 2 3 3 3 Tf not OK repair wiring and or connector w w www w 3 3 3 3 3 3No Replace ATF thermosensor 3 3 3 3 3 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Yes Replace EC AT control unit 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3No Intermittent poor connection 3 3 Check for cause 3 3 3 3 U Fig 7 Service Cod ATF THERMOSENSOR 94055428 56 Circuit Diagram SERVICE CODE 57 DIAGNOSTIC TABLE WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM 0
63. G 3 16mm 3 13 4 x 2 4 3 LB57 61 J1X 3 3 3 3 3 axial 3 3 3 3 Be UK 5 w2 95 x1 95 LB57 61 J1X 3 2 2 5 oci 3 3 6 1 x 1 8 3 C003 6 7 3 5 7 J U NOTE Part numbers ending in J1X are delivered in quantities of 10 A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM See Fig 11 for O Ring Identification 929 1994 95 95G51942 Fig 11 1994 95 929 O Ring Identification 1995 96 PROTEGE O RING DESCRIPTION TABLE
64. 3 Part Number Description Qty Applicable Models 3 0813 10 555A 3 O Ring 2 1 I Rotary Engine AAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAA AAAAAAAAAAAAAAAAAAAU WARRANTY INFORMATION NOTE This information applies to verified customer complaints on vehicles covered under normal warranty Refer to the SRT microfiche for warranty term information The Operation Numbers Labor Hours below include complete transmission R amp R flywheel or counterweight R amp R and road test Warranty Type A Symptom Code 76 Damage Code Use Code Applicable to Problem Part Number Main Cause 0813 10 555A Quantity 1 Operation Number Labor Hours XX012XR1 2 9 FC M T XX012XR2 3 6 FC A T XX012XR3 3 7 FD M T XX012XR4 Z 4 7 FD A T END OF ARTICLE PARTIAL ENGINE LONG BLOCK AVAILABILITY CAT B NO 004 94 ARTICLE BEGINNING Article Text 1993 Mazda RX7 For www iluvmyrx7 com Saturday August 25 2001 09 36AM TECHNICAL SERVICE BULLETIN PARTIAL ENGINE LONG BLOCK AVAILABILITY All Mazda Models available as repair components and will repl ing a partial ntir When install Model 5 Category B Bulletin No 004 94 Date 3 9 94 Revised 6 21 94 DESCRIPTION Partial engi
65. The program will take approximately seven weeks to complete After ANNOUNCEMENT OS SST UPDATE PROGRAM 001 CAT ST NO 001 94 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 21PM that time the program will be terminated and no further updates will be performed Therefore if your dealer does not responded to the program within 2 weeks of receipt of its box or does not have a serviceable 49F0 18 902 harness adapter you will automatically be shipped a new 49T0 18 902 harness adapter Your parts account will then be billed 457 71 4 DETAILED PROCEDURES STEP 1 MONDAY A Fed Ex box is shipped Economy 2nd day to your dealer on the implementation date illustrated in the above table The box will contain an instruction order form return label with vendor s address and a return Fed Ex box STEP 2 WEDNESDAY Your dealer receives and unpacks the box If your dealer elects to participate in the program you A Complete the instruction order form and inserts into the return Fed Ex box with their old 49F0 18 902 B Complete th nclosed return label and applies it to the return box The box is then sealed C Your dealer telephones Fed Ex 800 238 5355 to pick up the sealed box the next day Thursday If
66. 3 3 FLUID 3 3 LEVEL 3 AAAAAAAAA AAAAAAAAAA 3 CONDITION AAAAAAAAAAAU 3 Refer to Part 2 3 U 3 3 below 3 3 3 U 3 AAAAAAAAAAAAAAR 3 Adjust Level 3 3 Milky 3 3 Burnt Particles 3 U U 3 3 Inspect Repair 3 3 Wash Engine And 3 3 Transmission 3 3 3 Transmission 3 3 Cooler 3 3 U U 3 3 3 3 Inspect For Leaks 3 U 3 Power Flush 3 AAAAAAAAAAAAAAA NO UAAAAAAAAAAAAA AAAAAAAAAAAAAAU 3 Refer to Part AAAAA Leaks Found 3 3 2 below 3 AAAAAAAAAAAAAAU AAAAAAAAAAAAAAAAU 3 YES 3 3 Record Location 3 3 Of Leak
67. U ORDER INFORMATION Use the following ordering procedures KENT MOORE J 35944 AMAZ AT Oil Cooler and Line Flusher J 41763 Adapter Kit optional J 35944 A A T Flusher which includes chrome plated brass tank one gallon of J 35944 22 flushing fluid enough for six flushing operations additional fluid can be purchased directly from RECOMMENDED A T COOLER LINE FLUSHING EQUIPMENT CAT ST NO 009 95 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM Kent Moore complete operating instructions Phone Number 1 800 345 2233 Fax 1 800 578 7315 You will be billed directly by Kent Moore OTC No 60081 M Portable Oil Cooler Torque Converter Cleaner J41763 Adapter Klt A T Oil Cooler and Line Flusher Phone Number 1 800 533 0492 Fax 1 800 455 7240 You will be billed directly by OTC SHIPPING INFORMATION Your order will be shipped directly from the manufacturer END OF ARTICLE WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC PROCEDU
68. vear Model 7 Engine P N 7 Gasket P N Remarks 31991 93 NAVAJO 3 NONE E NONE 3 i U EN PAINE 3 Year Model 3 Engine P N 3 Gasket P N 3 Remarks 3 1986 89 323 4X2 B630 02 300 3 8AB1 02 310 Does Not Fit 3 3 1 61 3 3 3 86 87 w Std 3 3 Steering amp A C AAAAAAARARARARAAAARARARAAAARARARAAAAAARARARAAAARARARAAIAIARARARARARAA 3 1988 89 323 4X2 WILL BE 3 8AB2 02 310 3 1 6L TURBO 3 AVAILABLE 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4x4 WILL BE 3 8AB2 02 310 3 2 3 3 AVAILABLE 3 3
69. DESCRIPTION A customer may complain of an unusual noise from the front suspension upper arm bushing when the vehicle moves from a stop Turning the steering wheel when the vehicle is stationary may also produce the noise REPATR PROCEDURE Verify the condition and replace the upper arm rubber bushing with a Me modified one designed to eliminate the noise See Figs 1 and 2 Note the asterisk on the modified part View A 94G50423 Fig 1 Modified Bushing Identification FRONT SUSPENSION UPPER ARM BUSHING NOISE CAT R NO 004 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 23AM Cut Away This Lip and Remove Bushing With Hydraulic Press Lubricate New Bushing With Soapy Water And Install With Press Rubber Bushings Upper Arm 94H50424 Fig 2 Front Suspension Upper Arm Assembly IT P Part Description st Part Number AAKAAAAAAAAAAAAKAAAAAAAAAKAAAAAAAAAAAAAAAAAAAAAAAA Rubber Bushing 2 one side 3 FDO1 34 480A ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAA NOTE Part number remains the same AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
70. A EL 3 ALL 3 Mazda 3 FWD ECAT 3 AAKAAAAAAAAAKAAKAAAAAAAAAAAAAAAAAAAAAABAAA A EL 3 ALL Mazda FWD ECAT 3 A HL 3 2 2 F2 3 Ja ARAAAAAAAAAAAAAAAAAAAA A HL 2 6 G6 Jat ARAAAAAAAAAAAAAAAAAAAA 1990 93 B2600 3 RAA 1991 94 Navajo 3 AX EL 2 6 G6 3 Ja 4 0 3 tco teo AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A4LD Ford RWD HAT RWD HAT 3 3 RWD 4WD ECAT RWD AWD HAT 3 AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAA LL SS MEN NN RR o E MM AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 ECAT Electronically Controlled Automatic Transmission HAT Hydraulically Controlled Automatic Transmission 3 3 3 NOTE MASH Hotline will provide information regarding vransmission availability for 1995 96 B Series vehicles A
71. NOTE 1 Power flushers require installation of a 5 micron filter 2 All of the above flushers require adapters attachments for Mazda vehicle applications 3 Questions regarding usage and applications should be directed to the flusher manufacturer Fig 1 AUTOMATIC TRANSMISSION DIAGNOSTIC PROCEDURES CAT 002 94 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM AUTOMATIC TRANSMISSION CHECK SHEET Dealer ORO Service Writer Dealer No Dete _ Customer s Name Dealer Telephone No __ s E Model Year Engine Mileage E Ug p VIN M Aftermarket Parts Installed Yes list if yes EM Customer Description Of Problem E D V Test Drive Vehicle Yes No Movement 12 3 4 R l Engine Temperature Cold Hot Al Noise 123 4 R_ 5 Road Condition Flat Hil Slip 1 2 23 34 43 32 24 o Vehicle Speed High__ Cruise__Low__ All__ Shocki 2 2 3 34 43 232 24 R is The Problem Intermittent Yes Flare 1 2 2 3 34 43 32 24 Is The Problem Occurring Now Yes No__ PROBLEM DESCRIPTION DIAGNOSIS Description Problem Duplicated Yes__ No__ Test Drive Yes No Serv Bulletin Relating To Problem list if yes Trans Flui
72. A AARAAARAAARA AAA AAA RAA AR 2 10 3 E 80 co A 3 A A AR AAA RAA AA AAA RAA AR 3 20 3 6 4 10 3 3 90 3 22 gt 1 9 3 AARAAARAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAAARA 3 30 4 9 1 9 3 LOO 01 9 co 1 5 AARAAARAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAARA 3 40 3 6 0 L10 3 0 28 1 3 3 AARAAARAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAARAAARAAAARAAARAAARA 3 50 3 0 4 7 L20 2 0 67 Lo 2 AARAARAARAAARAARAAAAAARAARAAAAAARAAAAAARAARAARAAARAAAAARAAARAAAAAAAA 60 3 ud ceu 3 2 ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM U 2 Check resistance between E2 and Vc See Fig 4 Standard Value 200 400 ohms wer Do Not Loosen These Screws NOTE If the screws are loosened or re moved the warranty claim will be rejected 9415303 1 Fig 4 Air Flow Meter Resistance Check NOTE U
73. B applied 3 Continuity 3 3 B not applied 3 No continuity 3 U NOTE Battery positive voltage 4 If not as specified replace the cooling fan relay For additional wiring schematic information see Figs 12 and 13 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM Type Body Side Type Type Front L Cae ea ie A 7g Z 2 e ci i 9 asassdussqhssd4sss VA 98B51624 Fig 11 Terminals A and B to E Ce ee x O gt 5 c Sos mre sh 5 LL Copyright 1998 Mitchell Repair Information Company LLC SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 39AM Saturday August 25 2001 09 1 XY 8661 0 Z 56 9 passa CHER x31 c O31 33 893 RJ UH2LIAS 13 L 331139 O3 384 SSYdA8 H Y 180d WJ 2 331738 SSYdAB Ul LEIS 113 JANYA 010N310S 62 18 3 OION310S 92 18 3 GIONZTOS 42 18 3 01
74. 3 6 Disconnect negative 3 Yes Replace EC AT control unit 3 3 3 battery cable for at least 3 or engine control unit 3 20 seconds AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Connect battery cable and No Intermittent poor connection WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM 3 3 recheck for service cod 3 3 Check for cause 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU REDUCE TORQUE SIGNAL SLIP LOCKUP SIGNAL E EC AT ENGINE CONTROL UNIT CONTROL UNIT TORQUE REDUCED SIGNAL 94655448 Fig 8 Service Code 57 Circuit Diagram SERVICE CODE 58 DIAGNOSTIC TABLE 3 Service Code 58 3 Atmospheric Pressure Sensor AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Step Inspection 3 Action 3 3 1 3 Are there any poor 3 Yes Repair or Replace connector 3 3
75. 3 NAPA Temp Products 3 ATC 1100 5000 3 Nissan SPX Robinair 3 J 38100 NI 17400NIS 42 17250 NI 3 3 17401NIS 17403NIS 3 3 OTC SPX Robinair 3 OEM 1380 1396 1412 3 3 3 48463 1420 48158 3 Ozone Environmental 3 R 6A OS 1000 08 4000 5 2000 3 3 Industries Inc 2 5 P amp F Technologies PF 8 3 2 Power Manufacturing 3 R 12a 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Promax Industries Inc 3 Roger 1 f
76. RC ZP E94A E94 E94 A A 3 3 3 0000 1 ARAAAAAAAAAAARAA 0000 1 AAAAAAAKAAAAAAAA 0000 1 ces B2000 3 E94A 3 0000 0000 1 1979 82 626 i RC ZP E94 A 3 0000 1 8 094 8 094 8 094 8 094 A A A A 1979 85 1981 85 RX 7 RC ZE GLC FWD i RC ZE AAAAAAKAAAAAAAA E97 3 AAAAAAAKAAAAAAAA E98 3 AAAAAAAKAAAAAAAA 0000 1 0000 1 1986 87 323 1983 87 626 FWD 1983 87 B2000 RX 7 1986 91 All Models 3 3 3 3 RC ZP RC ZP E98 E02 3 3 3 3 0000 1 RC ZX99A
77. U WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty Warranty Type A Customer Comment Code 62 Damage Code 97 Part Number Main Cause FDO1 64 170A Quantity 1 Operation Number TO416XRX Labor Hours 03 gt HES END OF ARTICLE HOOD RELEASE INOPERATIVE DIFFICULT TO OPEN REPAIR MT 0295 05 Copyright Article Text 1993 Mazda RX7 For www iluvmyrx7 com 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 37AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN HOOD RELEASE Model 5 1993 95 Mazda RX 7 Category Mazda Tips Bulletin No MT 0295 05 Date February 1995 DESCRIPTION If the hood release is inoperative or very difficult to pull even though the release knob moves all the way out you do not need to replace the cable or the lock adjustment of the hood lock The problem is caused by poor Follow the procedure listed below to remedy the situation NOTE If the hood will not op n remove the release knob bracket from Ct he dashboard separate pull the inner cable the cable end and the knob then firmly 1 Adjust the location of the hood lock Latch the striker into the center of the lock Check the clearance of the striker latch to the lock You can see the lock then adjust the location of clearance is even S Fig between the hood and bump
78. P Part Number Description Quantity 3 3 3 3 New E Old 3 3 3 3 32 125A FDO1 32 125 3 Boot Rack Left 3 E Ah AAARRAAAARAAAARAAAARAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAA 3 FDO2 32 125A FD02 32 125 3 Boot Rack Right 3 2 NOISE WHEN TURNING STEERING WHEEL NEW RACK BOOTS CAT N NO 002 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 24AM WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty Warranty Type A Customer Comment Code 82 Damage Code 9B Part Number Main Cause See PARTS INFORMATION TABLE Related Parts See PARTS INFORMATION TABLE Quantity See PARTS INFORMATION TABLE Operation Number NO205BRX Labor Hours 2 3 Hrs Includes front wheel alignment and adjustment END OF ARTICLE RIDE QUALITY PROPER TIRE INFLATION CAT Q NO 002 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Compa
79. G 16mm 3 13 4 x 2 4 3 LB57 61 J1X 3 1 3 3 axial 3 3 3 3 AU NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 9 for O Ring Identification 1995 MAZDA RX 7 95H52016 Fig 9 1995 96 RX 7 O Ring Identification 1992 93 929 O RING DESCRIPTION TABLE 3 Pipe O Ring 3 Part Numbers 3 Quantity 3 Ring 3 Size 3 Size DX T 3 and 3 Per 3 3 Code 3 3 3 Kit Numbers 3 Vehicle d A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM 3 G 16mm 13 4 x 2 4 3 LB57 61 J1X 3 3 5 3 3 axial 3 3 3 3
80. 7 3 unit connectors 3 No 3 Go to next step AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 2 3 Connect a circuit tester 3 Yes Check wiring and go to 3 3 3 to terminals 2F and ground 3 Step 5 3 3 as shown in Fig 15 7 x 2 3 Is output voltage of 2 3 3 3 3 solenoid valve lockup 7 3 control at EC AT control No go to next step 3 unit OK 3 2 3 3 Acceptable voltage 3 3 3 Battery voltage lockup 3 3 3 3 Below volt no lockup 3 3 3 ARAAAAAAAARAAAAAAARARAAAARAAAARAAAAAARARAAAAAAAAAAAAAAAARARAARARAAAAA 3 3 Disconnect 20 pin EC AT 3 Yes Go to Step 5 3 3 control unit connector 3 3 3 3 Is resistance between 2F A A AAAAAAAAAAAAAAAAAAAAAAAAAAAA A 3 terminal and ground OK 3 No 3 Go to next step 2 3 3 Resistance 20 40 ohms 7 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 Disconnect solenoid 3 Yes Check wiring and connectors connector 3 3 from control unit to Is resistance between lockup control solenoid w w w 3 3 3 3 3 3 3 3 3 3 3 ground and terminal A of 3 If OK go to next step 3 solenoid valve lockup If not OK repair wiring 3 control OK 3 3 and or connector 3 Resistance 20 40 ohms AAAAAAAAAARAAAAAAAAARAA
81. U NOTE A UL Multiple Listing referred to as private labeling by the industry is the formal publication of the name of company that appears on equipment that is basically UL Listed for another company It would be similar to a private brand except that the basic company name need not appear anywhere on the product This equipment has been evaluated to determine the minimum purity specifications for recycled CFC 12 for use in mobile automotive air conditions systems Such equipment is provided with the following auxiliary marking Design Certified by Underwriters Laboratories for Compliance with date to indicate that the equipment has been investigated for compliance with the applicable SAE requirements TABLE 2 SUBSTANTIALLY IDENTICAL RECOVER RECYCLE EQUIPMENT TABLE 2 SUBSTANTIALLY IDENTICAL RECOVER RECYCLE EQUIPMENT UAAAKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARBAAAAAAAAA 3 Substantially Identical 3 Recover Recycle Equipment 7 HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM REJUVENATOR ST 100 and ST 1000
82. U VEHICLE SUBJECT TO RECALL FLOW CHART RARARARARAAAAARARARARARARARAAA B AAAAAAAAAAAAAAAAAAAAAAAAAARA Is The vehicle subject to No further action required 3 Recall No 60504 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAU U 3 YES AAAAAAAAAAAA AAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAR 3 Are there recall labels AAYESAA No further action required 3 indicating both recalls 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 No 60504 amp No 54407 have 3 been completed 3 U NO UAAAAAAAAAAAAAAAAAAAAAAAAA UAAAAAAAAAAAAAAAAAAAAAAAAAAKA 3 Is vehicle subject to AAANOAA Follow Repair Procedure A 3 Recall No 54407 3 3 3 AAAAAAAKAAAAAAAAAAAAAAAAAAAAAAU 3 Replace Fuel Hoses 3 YES 3 3 AAAAAAAAAAAA AAAAAAAAAAAAAAR 3 3 Has recall repair No 54407 AAYESAA 3 5 been performed 3 3 U NO UAAAAAAAAAAAAAAAAAAAAAAAAA 3 Does vehicle have any AAANOAA Follow Repair Procedure 3 Coolant Leakage 2 B C amp E 3
83. National Institute of Automotive Service Excellenc 13505 Dulles Technology Drive Herndon Virginia 22071 3415 703 713 3800 Approval Date 6 29 92 New York State Association of Service Stations and Repair Shops Inc Automotive Technician Training Program 8 Elk Street Albany New York 12207 518 434 6102 Approval Date 8 12 92 Rancho Santiago College 1530 West 17th Santa Ana California 92706 714 564 6661 Approval Date 8 12 92 Refrigerant Certification Services 8203 Willow Place South Houston Texas 77070 9998 800 597 9291 Approval Date 4 19 93 NOTE Only RCS te
84. OK 3 No 3 Go to next step 3 Resistance 500 1 000 ohms 3 3 3 WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM 3 4 3 Disconnect speed sensor 1 Yes Check wiring and connectors 3 3 connector 3 from EC AT control unit to 3 3 3 Is resistance of sensor OK speed sensor 1 3 3 3 3 If OK go to next step i 7 3 Terminal 3 Resistance If not OK repair wiring 3 3 3 AAAAKAAKAAAAAAAAAAAAAAAAAA 3 3 and or connector 3 A B 3 500 1 000 7 infinity 3 Replace speed sensor 1 5 7 2 A C infinity I 3 3 5 3 Disconnect negative 3 Yes Replace EC AT control unit 3 3 battery cable for at least 3 3 3 3 20 seconds AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Connect batter
85. 3 2 3 3 3 3 3 3 3 3 3 AAAAAAAAAAAAAAAAAAAAAA 3 3 gt Pipe 3 O Ring 3 Part Numbers Ring 3 Size 3 Size D X T 3 and 3 Code 3 3 3 Kit Numbers AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAA 3 B 3 63 648 56 15 3 LB52 61 J1X 3 C 35 3 8in 7 7 65 x 1 78 3 L853 61 J1X 3 D J 12mm 10 8 x 1 78 3 LB54 61 J1X 3 E 12mm LOEB LB55 61 J1X 3 3 axial 3 3 3 F 3 16mm 14 0x 1 78 LB56 61 J1X 3 G 3 16mm I344 3244 0 LB57 61 J1X 3 3 axial 3 3
86. U WARRANTY INFORMATION Applies to Vehicles Covered Under Warranty Warranty Type Code A Customer Comment Code 82 Damage Code 97 Part No of Main Cause FDO1 58 601B 59 601B Operation No S1004XRX Labor Hours 0 6 hrs one side END OF ARTICLE WINDSHIELD FOG OR FILM MT 0397 04 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 45AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER WINDSHIELD FOG OR FILM Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0397 04 Date March 1997 DESCRIPTION Some customers may complain of a fog or a film on the interior of the windshield This is a harmless by product of chemicals used to produce many interior trim components and can be easily removed from windows with glass cleaner END OF ARTICLE WINDSHIELD STONE CHIPPING INSPECTION CAT S NO 037 96 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 45AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WINDSHIELD STONE CHIPPING INSPECTION Model 95 All Mazda Models Category S Body Bulletin No 037 96 Date August 10 1996 DESCRIPTION Windshield cracks caused by stone chips are not covered under the new vehicle warranty Service
87. 3 Can be replaced by any letter or number 3 U VEHICLE SUBJECT TO RECALL FLOW CHART RARARARARAAAAARARARARARARARAAA B AAAAAAAAAAAAAAAAAAAAAAAAAARA Is The vehicle subject to No further action required 3 Recall No 60504 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAU U 3 YES AAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Are there recall labels AAYESAA No further action required 3 indicating both recalls 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 No 60504 amp No 54407 have 3 been completed 3 U NO UAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAARAR 3 Is vehicle subject to AAANOAA Follow Repair Procedure A 3 Recall No 54407 3 3 3 AAAAAAAKAAAAAAAAAAAAAAAAAAAAAAU 3 Replace Fuel Hoses 3 YES 3 3 3 3 3 Has recall repair No 54407 AAYESAA 3 5 been performed 3 3
88. U AAAAAAAAAAAAAAAAAAAAA NO RAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Symptom Duplic U 3 MES ated AAAAA Check M Tips On Line Service Manager Contacts the 8004 3 3 If Necessary AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM 3 U UAAAAAAAAAAAAAAAAAAA NO AAAAAAAAAAAR 3 Normal Condition AAAAAAAAAAAAAAA Write R O 3 U 3 YES 7 AAAAAAAAAAAA AAAAAAAAAAR AAAAAAAAAAAA AAAAAAAAAAA 5 Drive Other Vehicle To 3 Technician Review R O 3 Confirm Operation 3 AAAAAAKAAAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAAAAAAAAAAA No U AAAAAAAAAAAAAAAAAAAAAAAAAA 3 Contact Service ManagerAAAAAA Understand Complaint A 3 Or Adviser 3 Road Test If Necessary AKAAAAAAAAAAAAAAAAAAAAAAAU AAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 AAAAAAAAA AAAAAAAR NO 3 Is A T Fluid In AAAAAAAAAAAAAAAAAAAAAAA Good Condition 3 3 AAAAAAAAAAAAAAAAAAAU 3 YES
89. U Measure Plate Does Not Move Smoothly YES NO According to Service Bulletin instructions Category No ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM According to DSM or Hot Line Authorization Authorization Other Technician s Signature Date NOTE Attach the check sheet to the repair order If requested to return the failed air flow meter to Mazda attach a copy of the check sheet and repair order FUEL PUMP OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER UAAAAAAAAAAAAAG Diagnostics i iD AA AARRAARRRAARAAU MMA 3 UARARARARAAAAA UAAAAAAAAAAAAAAAAY 3 Results AA No Trouble A Contact Region AAA Found 3 Hot Line 3 3 3 Trouble Found 3 3 3 3 3 AAAAAAAAAAAAAAAA 7 3 Complete 3 3 Hot Line a 3 Check Sheet AAAAAAAAAAAAAAA Instruction 3 3 3 Order Part Authorized AAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAU Replacement 3 3 3 Auth No Required AAAAAAAAAAAU AAAAAAAAAAAAAAAAAAA Review 3 Receive Parts 3 Diagnostics U UA 3 3 3 AA UA 3 3 AA
90. 3 25 30 3 2 7L 3 AKAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAABAAAAA 3 30 35 3 2 2L 3 AKAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAABAAAAA 3 35 40 3 6L 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 40 45 3 1 0L 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 52 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM tration Use Hydrometer To Measure Concentration AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU tank and close the overflow hole in See Fig 72 56 Remove the cap from the surge the surge tank neck with tape Fig 72 Cover Overflow Hole 57 Install the radiator pressure tester on surge tank See Fig 73 58 Apply 15 psi 94E59356 Install radiator tester and apply 15psi Verify that pressure holds Radiator Pressure Tester Application Fig 73 59 Verify that pressure holds RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 53 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM NOTE If the radiator coolant pressure has dropped locate the leak and repair as necessary Retest after repair following the above procedures After confirmation that no leaks ar
91. AR AA RA RAR RARARRARARRARARRARARARRARRARARARRARARRARAARARAR AR 3 Front seal RPL 3 RPL 3 RPL 3 RPL 3 RPL 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM 3 Ext hsg seal 3 RPL 3 RPL ECL OO les remet ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Pan gasket RPL 3 RPL 3 RPL RPL RPL AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA Axle seals 3 3 3 PL 7 RPL RPL 3 AARAAAARAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAARAAAAAA mm ARAAAAAARAAAAAAAAAAAA 3 Oil filter strainer 7 RPL S RPL 3 RPL 3 RPL 3 RPL 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Electrical solenoids RPL 3 RPL 3 RPL 3 RPL 3 RPL 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAARAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Electrical switches RPL s RPL RPL 3 RPL 3 RPL 3 ARAAAAAARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Vehicle speed sensor RPL 3 RPL 3 RPL RPL RPL 2 ARAAAAAARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Turbine speed sensor RPL RPL 3 RPL 3 seal En 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
92. 3 Fluoro Tech Inc 3 Fluoromizer 3000R FM3000R FM3000 3 3 3 With RM3 module Flouromizer 3000 3 3 FMA000 12 amp d 3 Ford Motor Company 3 158 00001 00002 01400900 3 3 3 02300100 3 3 Ford New Holland 3 FNH00140 FNH00141 FNH00335 3 3 SPX Robinair 2 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Four Seasons 3 598 np xx 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Four Seasons 59900 59901 3 3 General Motors SPX 3 17250B I 3 Robinair 3 3 3 Honda SPX Robinair 3 J 3810 CH 3 IG LO Inc 3 1400 1500 3 Subsidiary of d 3 3 Valvoline Inc 3
93. Warranty Type Code A Customer Comment Code 03 Damage Code 99 Part No of Main Cause N3A1 8 881R N3A2 18 881R N3A3 18 881R N3A4 18 881R Operation No FO812XRX Labor Hours 0 3 hrs END OF ARTICLE HESITATION WHILE DRIVING CHECK ENGINE GROUND STRAP CAT F NO 005 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 00AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN HESITATION JERKING BUCKING WHILE DRIVING Model 5 1993 95 Mazda RX 7 Category F Fuel amp Emission Control System Bulletin No 005 97 Date March 10 1997 DESCRIPTION A jerk or bucking condition may occur under any of the following conditions Under light to moderate acceleration Cruising at engine speed of 2000 2200 rpm A C ON This concern may be caused by improperly grounded engine harness creating high resistance in the engine ground circuits This condition affects the fuel control system Customers complaining of this concern should have the vehicle inspected and if necessary repaired according to this bulletin REPAIR PROCEDURE 1 Clean and retorque harness ground See Fig 1 a Locate ground on left side of engine mounted to bracket behind A C compressor Refer to the applicable BETM or wiring diagram b Tightening Torque 7 11 N m 69 5 95 4 in lb 2 Cle
94. IZ Upshift _ TEE D 2 3 Upshift NEM AS DORS MONS E 3 4 Upshift m e m F Downshifts PERS G Kickdowns _ c Noise Vibration Clunk _ Whine _ Buzz Other Condition Occurs Hot _ Cold Frequency Intermittent __ Always 3 TECHNICIAN DIAGNOSES Are There Any Vehicle Modifications __ Yes No If Yes describe AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 21 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM Visual Inspection Note Leaks Fluid Condition Burnt _ Normal Fluid Level Correct _ High _ Low A Self Test Codes Before Repair KOEO CONT KOER B TP FIPL Gage Block Setting Solid Tone OK Slow Beep Low Adjustment Fast Beep High Adjustment C Line Pressur Record Applicable Data IDLE WOT P N A R _ N A OD D 2 1 a Was Transmission Tester used for Diagnostic __ Yes __ No Shift Linkage TR MLPS Setting __ Correct __ Incorrect Metal In Pan __ Yes No 4 OTHER POWERTRAIN ELECTRICAL EEC SERVICE PERFORMED 5 TRANSMISSION IDENTIFICATION Removed From Vehicle Original Unit _ Remain Unit __ Part No Serial No Model No 6 REPLACEMENT TRANSMISSION IDENTIFICATION Installed Into Vehicle Installation Date Service Part No Serial No BEFORE REQUIRED R
95. LIST OF APPROVED SECTION 609 CERTIFYING ORGANIZATIONS OZONE PROTECTION HOTLINE TOLL FREE 800 296 1996 EPA S OZONE DEPLETION WORLD WIDE WEB SITE http www epa gov docs ozone index html September 22 1995 This list will be updated when other technician certification programs are approved Section 609 covers technician certification in the motor vehicle sector only An asterisk indicates that the program offers home study NOTE Ryder Trucks formerly offered a certification program Retailers should continue to accept Ryder cards C F C Reclamation and Recycling Service Inc P O Box 560 Abilene Texas 79604 915 675 5311 Approval Date 3 31 93 The Greater Cleveland Automobile Dealers Association 6100 Rockside Woods Boulevard Suite 235 Independence Ohio 4413
96. RC ZX1 0000 8 9A MX 3 1 6L 1990 95 1990 91 CDM 1992 95 Miata 3 9205 3 MX 3 1 30 RC 2E 929 3 RC ZE RC ZE21 3 Su 0000 8 121A 0000 8 122A E25 3 0000 8 125A E26 3 0000 8 126A PARTS BULLETIN SPARK PLUG COIL WIRE SET NO T 1 6 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 00AM 1991 oe
97. Cooling fan shuts off 3 Memory needs cleared when the key is turned Disconnect the battery and start off during the fan 2 fan test over test 2 w w w gt 3 3 3 3 Cooling fan comes on 3 If the vehicle was produced before A 3 3 immediately when the April 1 1993 VIN of JMIFD331 3 key is turned on and P0210660 or less 3 3 3 3 3 3 3 3 3 the check connector is The fan should come on immediately 3 grounded when the key is turned on 2 3 3 3 3 ave the key on and the fan perating for at least 150 seconds L Turn the key off and proceed with 3 3 3 3 3 3 3 3 he test AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Fan operates only on 3 Check that the harnesses with the 3 3 medium speed during fan Black wires are connected 3 3 test 3 NOTE The other two 2 harnesses 3 are interchangeable ARAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU COMPONENT TROUBLESHOOTING AND INSPECTION PROCEDURE 1 Perform Spark Plug and Ignition Coil Inspection 2 Intake System Inspection check the following If the air hose is coming off If oil is pres
98. When reassembling replace the intake manifold gasket with a new one Gasket N3A1 13 112 18 Remove the following parts shown in Figs 9 amp 10 94D59322 Fig 9 O2 Sensor Coupler on the ACV 94E59323 DO NOT DAMAGE Fig 10 ACV Vacuum Tubes 19 Remove the nut shown in Fig 11 Remove the thr way solenoid RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM NOTE Do not remove the vacuum tube from the solenoid 94F 59324 Fig 11 Three Way Solenoid Nut to be Removed 20 Remove the oil filler pipe See Fig 12 Tightening torque 70 100 kgf cm 61 86 in lbf ww Y W 94G59325 Fig 12 Oil Filler Pipe Identification 21 Remove the ignition coil assembly Remove the four nuts shown in Fig 13 Tightening torque of the nuts for reassembly Tightening Torque 70 100 kgf cm 61 86 in lbf Fig 22 Fig NOT RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 XS Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM ATP E II ra IS UU 1148 3 AR E gt ETE 94H59326 ACV Removal 13 Four Nuts
99. 8AGB 02 31 8AGB 02 3 3 3 0 ARAAAAAAAAAAAAAAAAAAA 0 3 3 3 3 ARAAAAAAAAAAAAAAAAAAA 0 3 3 3 3 FS71 02 300A 3 8AGB 02 3 3 ARAAAAAAAAAAAAAAAAAAA 0 3 3 3 3 A T 3 1993 94 626 MX 6 2 5L KLY1 02 300A 3 8AE3 02 31 3 ARAAAAAAAAAAAAAAAAAAA 0 3 3 3 U 929 NEW ENGINE AVAILABILITY PARTS TABLE 3 Year Model 3 3 Engine P N Gasket P N 3 3 Remarks PARTIAL ENGINE LONG BLOCK AVAILABILITY CAT B NO 004 94 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 36AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 31988 89 929 3 0L SOHC JE15 02 300 3 8AH1 02 310 3
100. gt 40 45 5 3 01 3 Use Hydrometer to Measure Concentration AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU PRESSURE TEST COOLING SYSTEM 52 Remove the cap from the surge tank and close the overflow hole in the surge tank neck with tape See Fig 30 mo E Cover Overflow Hole 98051674 Fig 30 Cover Overflow Hole 53 Install the radiator tester on the surge tank See Fig 31 RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 25 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM DUI Install Radiator Tester And Apply 15psi Verify That Pressure Holds 98D51675 Fig 31 Radiator Pressure Tester 54 Apply 15 psi 55 Verify that pressure holds NOTE If the radiator coolant pressure has dropped locate the leak and repair as necessary Retest after repair following the above procedures After confirmation that no leaks are present remove the tape from the overflow hole and install the pressure cap AFFIX THE CAMPAIGN LABELS 56 Affix the label onto the driver s side door for future confirmation that the campaign has been completed on this vehicle IMPORTANT If the water pump was replaced during the campaign affix an additional recall label on th
101. 1995 1993 1995 1995 1993 1995 1995 1995 1995 1995 93 Nava jo 3 cdd eM e CUP AE 626 2 5L 3 RC ZE 3 94 626 MX 6 2 0L 3 626 2 0L A T 3 626 MX 6 2 0L M T 95 RX7 s RC ZE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Millenia 3 RC ZE AKAAAAAAAAAAAAAAAAAAAAAAAAAAAA MX 3 1 8L 3 RC ZE A A AAAAAAAAAAAAAAAAAAAAAARAAAAA MX 3 1 6L RC ZE A A AAAAAAAAAAAAAAAAAAAAAARAAAAA Protege 1 8L 3 RC ZE Protege sob RC ZE END OF ARTICLE 3 ZZLO 8 140 AAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 E28 0000 8 128A E32 3 0000 8 132A RC ZX29 3 0000 8 129A RC ZX4 3 0 0000 8 140A
102. 3 3 Pipe 3 O Ring 3 Part Numbers 3 Quantity 3 Ring 3 Size 3 Size D X T 3 and 3 Per 2 3 Code 3 3 3 Kit Numbers 3 Vehicle 3 3 A 3 8mm 3 63 9 x 1 78 3 LB51 61 J1X i 6 3 D 3 12mm 10 8 x 1 78 3 LB54 61 J1X 7 2 3 F 3 l6mm 3 14 0x 1 78 3 LB56 61 J1X 3 AU NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 12 for O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM Protege 1995 96 Fig 12 1995 96 Protege O Ring Ide
103. RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 28 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM VAAARARARRAAARARAARARARARRARAARARARRAAARARAARRRAAAARAAA 3 Symptom Cod 3 Description AARRAAARAAALAAK AAAAAAARARAAAAAAAAAARAAARARAAAARARARAAAA 3 09 3 Engine Overheat 3 AAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 11 3 Engine Knocking 1 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 61 3 Does Not Switch On AAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 62 N Does Not Switch Off AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA gt 64 3 Improper Operation 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 65 k Improper Indication 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 77 3 Water Leak Coolant Leak 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 78 3 Air Exhaust Gas Dust Light Leak z AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 92 Broken 3 U WARRANTY INFORMATION TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Nature 3 New Vehicle Retailed 3 Retailed E 3 3 In Inventory 3 Vehicles
104. FEY1 02 300 3 3 3 3 3 3 3 3 8AG2 02 31 ARAAAAAAAAAAAAAAAAAAA 0 Requires th 3 replacement of the Heat c Unit G607 18 510 3 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 3 3 FEY2 02 300 8AG3 02 31 1988 89 626 MX 6 NON T 3 3 T 3 1990 92 626 MX 6 NON T al w w 31993 94 626 MX 6 2 0L AR ANTE 31993 626 MX 6 2 01 31994 626 MX 6 2 01 w 3 3 URBO URBO 3 URBO 3 TURBO M T A T 3 3 F2Y1 02 300 3 8AG4 02 31 3 3 0 ARAAAAAAAAAAAAAAAAAAA 0 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 F2Y2 02 300 3 3 F2Y4 02 300 3 UR 8AG5 02 3 8AG4 02 31 3 3 10 ARAAAAAAAAAAAAAAAAAAA 0 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 F2Y5 02 300 3 02 300A 3 FSO1 3 FS01 02 300A 3 8AG5 02 31
105. 8 103A E06 3 0000 8 103A 1987 93 B2600i 1989 94 MPV 1987 93 B2200 1990 94 Protege 2 6L 3 2 6L 1988 92 626 MX 6 0000 1 1 8L DOHC 1988 94 323 Protege 1 6L amp 1 8L SOHC 3 3 3 3 3 3 RC ZE 7 3 0000 8 04 A RC ZE17 RC ZX12 RC ZE94A RC ZX18 9 3 3 3 3 3 3 3 0000 8 104A 0000 8 105A 0000 8 094A 8 118A
106. Model 5 All Mazda Models Through 1995 Category E Bulletin No 001 95 Date April 2 101995 NOTE This bulletin replaces Service Bulletin Cat P 006 94 dated Sept 1994 DESCRIPTION Customers who complain of vibration or pulsation in the steering wheel brake pedal floor or seat while applying the brakes may be experiencing symptoms of brake judder Judder is caused by Disk Thickness Variation DTV rotor run out and or rotor surface rust which leads to DTV This bulletin describes the causes and corrections for each condition CAUSES OF JUDDER 1 Disc Thickness Variation DTV DTV creates a vibration pulsation during application of the brakes DTV will increase with mileage accumulation if the run out of the disc is excessive 2 Disc Rotor Run Out Run out or rotor wobble leads to DTV It is corrected by precision machining to bring the run out within specification 3 Rotor Surface Rust Under certain conditions storage or use in extreme environments the surface of the brake rotors may become rusted in the pad non contact area If this I corrosion penetrates the rotor surface deeply enough it will not wear or rub off during normal use This will cause DTV CORRECTION In order to effectively correct brake judder rotor surfaces must be precisely machined Mazda has evaluated both on and off car brake lathes and has determined that on car lathes are more precise an
107. Install the hose white mark side within five minutes after applying adhesive NOTE Before installing the hose degrease the pipe for better adhesion Fuel hose N371 13 415 White pain 94F59332 Fig 19 Installing Hose on Inlet Side of Primary Fuel Distributor Submerging Hose End with White Mark into Adhesive 27 2 Install the clips on the hose of the inlet side of the primary fuel distributor NOTE Use two clips on the fuel distributor side Place the fuel distributor side clip claws on the top and the other one on the bottom For the directions of the clip claws see Figs 20 and 21 Insert the hose to the pipe bulge Match the edges of the clip and the hose end Replace all hose clips with new ones Do not use clips other than those included part number below Be care ul not to place the clip on the pipe bulge Clip N3Z1 13 157 x 2pcs with Red colored holder Protector N3B7 1 3428A RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 16 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Place the fuel distributor side clip claws on the top and the other one on the bottom 94G59333 Insert the hose to the pipe bulge NO CLEARANCE Match the edges of the clip and the hose
108. U YES 3 Voltage is Greater Than AAAAAAAAAAA Return To Service 12 4 Volts AAAAAAAAAAAAAAAAAAAAU U 3 NO 3 Recharge Until Voltage is 3 3 12 4V or Greater 3 U NOTE When testing in the vehicle turn the headlights ON for 15 Seconds to remove the surface charge before testing PARTS INFORMATION PARTS INFORMATION TABLE MAZDA FINISH LINE BATTERIES 3 Make Year 3 Model 3 OEM 3 Part Number T CA 3 3 3 3 3 ECA 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 981 85 3 FWD 320 3 0000 80 026R WB 525 3 GLC 3 981 85 Optional For Above 360 0000 80 0035 WB 550 3
109. U 1994 95 MX 3 1990 97 MX 5 MIATA 1993 95 RX 7 1992 95 929 TABLE Part Number i 3 AA AAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 9 inch 3 12 inch 3 VIN 3 Seat Position E 3 FDY5 57 63X 3 FDY6 57 63X All 7 Driver s amp Front 3 3 7 E Passenger s 1993 97 626 MX 6 1995 97 MILLENIA 1989 97 MPV 1988 89 929 TABLE AAAAAAAAARAAAARAAAARARAARAAAARARAAAAAAAAAAAAAAAAAAAA Part Number KAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 9 inch 3 12 inch 3 VIN 3 Seat Position 3 3 LBY2 57 63X 3 LBY3 57 63X All 7 Driver s amp Front i 3 3 Passenger s AAAAAAAAAAAAAA AAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAU SEAT BELT EXTENDER DESCRIPTION ORDERING INFO CAT S NO 032 96 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 41AM 1989 97 MPV INFORMATION TABLE
110. Incomplete connection Loos ma terminals Terminals that are pushed out of their connectors Water inside the connector Terminal corrosion Also check each related harness for damage END OF ARTICLE RECOMMENDED A T COOLER LINE FLUSHING EQUIPMENT CAT ST NO 009 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RECOMMENDED A T COOLER LINE FLUSHING EQUIPMENT NEW NATIONAL ACCOUNT Model s All Mazda Models with A T and ATX Category ST Special Tools Bulletin No 009 95 Date November 14 1995 RECOMMENDATION Service Bulletin Category K No 002 95 issue date 8 10 95 states that the automatic transmission oil cooler and lines must be flushed whenever performing a major transmission repair or replacement MMA has evaluated flushing equipment and is recommending Kent Moore s and OTC s products Both pieces of equipment provid ffectiv cleaning results and adapt to other manufacturer s vehicles There is a difference in procedures and costs between these two pieces of equipment MMA is offering you the choice of two recommended pieces of equipment so that you can best decide which piece of equipment fits your needs To assist in your decision the chart below lists the advantages and disadvantages betwe
111. nrs nrs nrs le both sides 1993 94 1995 FRONT BRAKES LABOR OPERATION TIME CODES 1993 1995 MODELS VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM Millenia Front Brakes Disc Plate s R amp R one side Labor Operation P0102ARX 0 5 hrs Front Brakes Disc Plate s R amp R both side Labor Operation PO208CRX 0 6 hrs Front Brakes Disc Plate s Machine on vehicl one sides Labor Operation P0113AMX 0 7 hrs Front Brakes Disc Plate s Machine on vehicl both sides Labor Operation PO113BMX 1 2 hrs Front Brakes Pad s R amp R one sides Labor Operation PO104ARX 0 5 hrs Front Brakes Pad s R amp R both sides Labor Operation PO104BRX 0 6 hrs 626 MX 6 Front Brakes Disc Plate s R amp R one side Labor Operation P0102ARX 0 3 hrs Front Brakes Disc Plate s R amp R both side Labor Operation PO208CRX 0 5 hrs Front Brakes Disc Plate s Machine on vehicl one sides Labor Operation P0113AMX 0 7 hrs
112. 3 Reason for replacement Terminal Voltage Out Of Specification Yes No RARARARARAAAARARARARARARARARARAAAAAAAARARARARARARARAAAAAAAARA Terminal Number 7 Voltage Reading Factory Specification 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 U According to Service Bulletin instructions Category No According to DSM or Hot Line Authorization Authorization Other ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Repair Type Technician s NOTE This c your s AIR FLOW METE Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM Warranty Customer Pay Signature Date heck sheet must be returned with the replaced part to ervicing PDC R OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER R
113. 3 Remove the vacuum tubes water hose and fuel hoses cutting the fuel hoses off at the position marked with scissors makes the work easier See Fig 46 NOTE Do not remove hoses other than 1 14 Remove the hoses on the sides indicated by arrows in Fig 46 Be careful not to damage any pipes When removing the hoses do not use any spray type lubricant 4 Move the vacuum pipe assembly toward direction D 5 When reassembling replace the hoses 1 2 3 4 5 6 7 8 10 and 11 with new ones RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 33 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM S RY WER Pe Hess re Mg 2 OOOO 9 I 3 2 9 SN i Fuel pipe ZZ main See step 32 2 Water hose Orange White ar So z Out w In 94J59328 Fig 46 Exploded View of Tubes amp Hoses for Modification 6 Replace the front throttle body water hose with a new one and attach it with two new hose clamps See Fig 47 NOTE Holder must be removed from clamps Water hose N3A1 13 692A Clamps 99287 1400P x 2 pcs Install throttle body hose using two 2 new clamps 94A59345 Fig 47 Installing Throttle Body Hose N3A1 13 692A Use Two New Clamps RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article
114. A EL 3 3 0L JE Jatco 3 RWD ECAT 3 RWD 4WD ECAT 3 AX EL 3 3 0L A HL 3 2 6L G6 Ja A EL 3 RE 3B 3 Ja AAAAAAAARAAAAAAAAAAAAA A EL 3 RE 3B Ja JE 3 Jatco 7 tco 3 ARAAAAAAAAAAAAAAAARAA tco 3 AAKAAKAAAAAAAAAKAAKA tco 3 RWD HAT RWD ECAT RWD ECAT 3 3 3 RAAAAAAARAAARAAAAAAAAARAARANARARARAAARARAR A EL 242 R2 Mazda FWD ECAT 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A EL 2 2 Turbo 3 Mazda 3 FWD ECAT 3 AAKAAAAAAAAAKAAAAAAAAAAAAAAAAAAAAAAAAABAAA A EL 3 2 0 ES Mazda FWD ECAT 3 AAKAAAAAAAAAAAAKAAAAAAAAAAAAAAAAAAAAAABAAA A EL 3 2 5 KL Mazda FWD ECAT 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A EL 2 0 3 1990 94 Protege 3 FAA 3 1990 96 Protege 3 FAA 3 FS 2 Ford FWD ECAT 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
115. AUDIO SYSTEM WIRING CHANGES MT 0794 07 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 23PM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER AUDIO SYSTEM WIRING DIAGRAM Model 5 1993 Mazda RX 7 Category Mazda Tips Bulletin No MT 0794 07 Date July 1994 DESCRIPTION The 1993 RX 7 wiring Diagram WG Pg 2 84 and Body Electrical Troubleshooting Manual BETM pg J1 11 incorrectly show a radio relay at connector J1 06 for the base audio system This relay only exists for the high grade BOSE audio system Mazda has corrected the 1994 publications pg 2 86 WD pg J1 11 BTEM to show J1 06 as the connector for the center speaker amplifier END OF ARTICLE BATTERY CHARGER CAUTION CAT 01 NO 012 99 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 23PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN BATTERY CHARGING CAUTION Model 5 All Mazda Models Category 01 Engine Bulletin No 012 99 Date April 19 1999 DESCRIPTION When attempting to charge a battery apply caution and remove it from the vehicle If a battery is charged in the vehicle with the battery cables connected excessive voltage produced by the charger may result in damage to the Powertrain Control Module PCM audio
116. For the direction of the clip claw see Fig 26 Do not use clips other than those included part number below Be sure to use two clips for the joint between the primary fuel distributor and the main fuel pipe shown with an arrow in Fig 15 NOTE For the direction of the clips claw s step 27 2 Clip Primary N371 13 157 x 2 pcs Clip with Red colored holder Place the fuel distributor side clip claws on the top and the other one on the bottom N3Z1 13 157 x 2 94C59339 Turn the clip claw sideways Dashboard side A g 8574 13 157 Fig 26 Connecting Hose Fuel Distributor amp Vacuum Pipe Assembly Place the Clip Claws in Opposite Directions RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 20 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 32 3 Replace the main fuel hose with a new one S Fig 27 NOTE The hose and the clips shown in Fig 27 should be replaced with new ones Be careful not to use the hose and the clips other than those included part numbers below Apply adhesive to the hose end short he arrow in Fig 27 then install i adhesive s step 27 1 end side only shown by To apply ct Insertion depth of both hose ends should be 25 30 mm Fuel hose N371 13 421 C
117. Operation Number Labor Hours MPV L4 K0101XRU 0 4 PV V6 2WD K0101XRU 0 4 MPV V6 AWD K0101XRU 0 4 AUTOMATIC TRANS COOLER LINE FLUSHING PROCEDURE CAT K NO 005 98 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM Millenia 2 3L K0101XRU 0 4 Millenia 2 5L K0101XRU 0 4 RX 7 K0101XRU 0 4 MX 5 K0101XRU 0 4 MX 3 L4 K0101ARU 0 4 MX 3 V6 K0101BRU 0 4 929 K0101XRU 0 4 626 MX 6 L4 K0101XRU 0 4 626 MX 6 V6 K0101XRU 0 4 Protege 323 2WD 6L amp 1 8L KO101XRU 0 4 Protege 323 2WD 1 5L KO101XRU 0 4 Protege 323 4WD K0101XRU 0 4 END OF ARTICLE AUTOMATIC TRANSMISSION DIAGNOSTIC PROCEDURES CAT K NO 002 94 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN AUTOMATIC TRANSMISSION DIAGNOSTIC PROCEDURES Model s All Mazda Models with A T Category K Bulletin No 002 94 Date 10 4 94 APPLICABLE MODELS All vehicles with automatic transmissions or automatic transaxles DESCRIPTION Follow the information listed in this bulletin when diagnosing automatic transmission transaxle problems or after installing a new or rebuilt transmission t
118. Civich pedal depressed Below Du Reduce torque ECAT 7 contial unt wen shiting hom Ysi 10 2nd or from Below 1 DV gal Test condhion Correct votage Tori input Tue Connected to Test condition Correct voltage Remark va v 1 2 sench Teland nd postion rvron swich ON m Omer Below EC3TCU Below Wiwe running AT nd to 3d wilh the tIvollie opening above 1 58 71 A When sip lockup with the thrattie opan Beiow ing below 05 8 Belew 10V gainon swach ON am Omer C aa or O D poston Below Ve 4 ton swich ON Vonage increase e when acceleraling Accelerator pedal depressed Below VOV He 93 06 tRalerencs Diagnose con necio C terminal Heaahgnt swich Brower molor po Paar detrosier swich ON Headtght swich Blower molor rear oeirosier swich are OFF ida Cold engine Approx OV Aller warm up 60 7 Ov H e Oscilloscope wavs 99 rT Deceleranon after warm up wr Engine speed 3000 rpm TELE Relererca dde Me Engne speed hoia 3000 ipm afe 5 Below seconde Wnuon swich ON 248 K Below 1 OV One Aperos kie Electrical cooling tan dose not V spar
119. FUEL PUMP CHECK SHEET Dealer Name Technician Number Vehicle Year Model M T A T VIN Repair Date _ Mileage Repair Order Number 1 Customer Complaint Was the customer s complaint verified Yes No Reason for replacement Fuel Pump Did Not Operate Yes No Insufficient Fuel Pressure yes No Maximum Fuel Pressure PSI Factory Specification ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM According to Service Bulletin instructions Category No According to DSM or Hot Line Authorization Authorization Other Technician s Signature Date NOTE Attach the check sheet to the repair order If requested to return the failed air flow meter to Mazda attach a copy of the check sheet and repair order CHARGING SYSTEM OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER RARARARAAARAA A Diagnostics AAAAAAAAAAAAAAAA AAAAAAAAAAAAAAU 3 MMA 3 AAAAAAAAAAAAAAAA 3 3 Results AA No Trouble A Contact Region AAA Found 3 Hot Line 3 3 AAAAAAAAAAAAAAAAAU gt Trouble Found 3 _ 3 3 3 AAAAAAAAA
120. EGR Vacuum Hose ACV Vacuum Hose Purge Hose Double Throttle Control Hose Double Throttle Control Actuator Hose tox 0X ab Hoses Water Hose RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM Pressure Sensor P Hose EGR Vacuum Hose 94159319 Fig 6 EGR amp ACV Vacuum Hose Water Hose amp Pressure Sensor Fig 7 Hose amp Vacuum Tubes Identification 94C59321 Jg Fig 8 Switch Identification 17 Remove th xtension manifold and throttle body RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM NOTE Cover exposed intake holes with shop towels Torque for re tightening the bolt Tightening Torque 160 230 kgf cm 139 199 in lbf When reassembling replace the intake manifold gasket with a new one Gasket N3A1 13 112 18 Remove the following parts shown in Figs 9 amp 10 S 94D59322 Ca 21 c Fig 9 O2 Sensor Coupler on the ACV DO NOT DAMAGE Fig 10 ACV Vacuum Tubes 19 Remove the nut shown in Fig 11 Remove the thr way solenoid RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504
121. IG LO Inc 3 1000 3 Subsidiary of 3 3 Valvoline Inc 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Infiniti SPX4 Robinair J 38100 INF 3 3 International Carbonics 3 RRR SS BH RRR 3 3 Inc now The Youngstown 3 3 Research and Development 1 Company YRD 3 3 3 James Kamm Technologies K 3333 K3333 TB AC 3333 3 3 Inc 3 3 3 John Deere SPX Robinair 3 JTO 2020 JTO 2021 JTO 2052 3 3 Kent Moore SPX Robinair J 38100 C J 38100 B J 38750 3 3 J 38550 B J 39770 42 17400 HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM 3 3 43 40015 HDE 43 40018 HDE 3 3 3 42 175250 C 43 40017 HDE 3 3 3 42 17350 C 43 40014 HDE 3 j 3
122. NOTE Replace the four insulators with new ones Insulator for primary N3A1 13 257 x 2 pcs Insulator for secondary NFO1 13 257A x 2 pcs 32 1 Apply adhesive to the hose end on the primary fuel distributor outlet side indicated by the arrow in Fig 25 To apply adhesive s step 27 1 N3A1 13 257 x 94B59338 Fig 25 Installing Fuel Distributors to the Engine 32 2 Connect the hose between the fuel distributor and the vacuum RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 19 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM pipe assembly See Fig 26 NOTE Replace the clips outlet side of the secondary fuel distributor with new ones Clip Secondary 8574 13 157 Clip with Pink colored holder For the direction of the clip claw see Fig 26 Do not use clips other than those included part number below Be sure to use two clips for the joint between the primary fuel distributor and the main fuel pipe shown with an arrow in Fig 15 NOTE For the direction of the clips claw s step 27 2 Clip Primary N371 13 157 x 2 pcs Clip with Red colored holder Place the fuel distributor side clip claws on the top and the other one on the bottom N3Z1 13 157 x 2 94C59339 Turn t
123. 3 Hitachi K5204 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Panasonic K6021 3 3 Yuasa E K7412 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAA 3 Mazda OEM Empak 3 KN212 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAA 3 Motorcraft p KM001 3 3 Mazda Replacement 3 KN999 x AKAAAAAAAAAAAAAAAAAAAAAAAAAABAAAAA 3 Includes Exide Interstate s AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU END OF ARTICLE WIRING DIAGRAM CORRECTIONS PAGES Z 37 amp Z 40 CAT Z NO 008 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 47PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WIRING DIAGRAM CORRECTIONS Model 5 1993 Mazda RX 7 Category Z Bulletin No 008 92 Date 11 19 92 DESCRIPTION The following figures represent revised wiring diagrams for the 1993 Mazda RX 7 Wiring Diagram service manual listed below Page Z 37 Correction to terminal 2K correction to terminal 3D Page Z 40 Correction to terminal 2K correction to terminal 3D Va Battery voltage The affected pages are Test Condition item Test Condition item Test Condition item Test Condition item Ve Battery vonage EN swich Clutch pedal released ignition swach ON Cut MT
124. 4 Install the vacuum pipes to the engine by tightening the bolts three pieces Tightening torque 160 230 kgf cm 139 199 in lbf Vacuum tubes 10 and 11 N3A4 20 344 x 2 pcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 45 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 0000 9 OW Orange Water hose ZA 6 White e D OUT 0m 94159343 Fig 64 Installation of Vacuum Tubes 35 Assemble the parts in the reverse order of removal PROCEDURE C REPLACEMENT OF THE FILLER CAP KIT NOTE Procedure C is continued from procedure B The parts listed in this procedure must be ordered separately and are not included with the Fuel Recall Parts Kit 36 Loosen the bolts of the filler cap body Remove and discard the body and cap Replace body cap and O ring with new ones from kit See Fig 65 Kit Part Number N321 15 S10B a gt 94D59348 Fig 65 Replacing Body Cap amp O Rings RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 46 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 37 Remove and discard the radiator cap from the sure tank and replace it with a Rad cap NOTE If the
125. one sides hrs on vehicle hrs P0209ARX 0 4 R amp R both sides PO214BRX 0 5 A M B R amp R one sides A t B late s R amp R one P0208ARX 0 6 s R amp R bot PO208BRX 0 8 s Machine P0214AMX 0 7 s Machine P0214BMX 1 2 nrs nrs side hrs h sides hrs on vehicl both sides hrs on vehicle hrs one sides both sides VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Rear Brakes Pad s Labor Operation Rear Brakes Pad s Labor Operation MX 3 Rear Brakes Disc P Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Pad s Labor Operatio Rear Brakes Pad s Labor Operatio 929 Rear Brakes Disc P Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Pad s Labor Operatio Rear Brakes Pad s Labor Operatio 323 PROTEGE Labor Operation Labor Operatio Rear Brakes Disc Labor Operatio Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Pad Labor Operatio Labor Operatio Rear Brakes Pad Labor Operatio s s Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com
126. uiia LI Seater U 7 Year Model 3 Engine P N 3 Gasket P N Remarks 3 1990 93 MIATA M T B61P 02 300 3 8AN1 02 310 3 3 3 1 6L 3 A T B64J 02 300 7 8AN1 02 310 3 31994 MIATA 1 8L BPE8 02 300 3 8ABC 02 310 3 3 U cM Mau M ECT PIECE U Year Model 3 Engine P N
127. 150 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 L95 3 A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAR A 3 B Series 3 150 3 3 3 195 3 3 3 95 3 AU MINIMUM VOLTAGE TABLE 3 Aprox Battery Minimum Voltage 3 Temperature 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA TOF 210 9 6V i 60F 15C 3 9 5V AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA k 50F 10C 3 9 4V 3 3 40F 4C gt 9 3V 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 30F 1C 3 9 1V 3 AAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAA 3 20F 7C 5 8 9 U If the voltage measures at or above the minimum proceed to step 5 If the voltage is below the minimum quick charge the battery for 30 minutes and load test If the battery remains below the minimum replace the battery and proceed to step 5 NOTE Battery inspection and charging procedures for Navajo vehicles are different than those outlined in this bulletin Refer to th
128. 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM as shown in Fig 31 amp Fig 74 SPECIAL NOTE Under separate cover a container of special adhesive was shipped to every dealer The adhesive was strapped with a note which clearly indicates that this adhesive is the only adhesive that can be used to carry out the repairs for this Recall Do not attempt to carry out this Recall unless you have the adhesive If your dealer has not received the adhesive please contact the Technical Hot Line at 1 800 268 9400 Initial quantities of the Fuel Hose Kit part number N3A1 13 S70 have already been shipped However pleas G a onfirm parts stock with each new customer that books n appointment to have this Recall completed In addition to the above mentioned parts the following parts will have to be ordered depending on which repair procedure s is required If Procedure A is performed no additional parts order is necessary If Procedure B amp C are performed order Throttle Water Hose Kit part number N3A1 13 500 and Filler Cap Kit part number N3Z1 15 S10B If Procedure B C amp D are performed order Throttle Water Hose Kit part number N3A1 13 500 Filler Cap Kit part number N371 15 S10B Thermostat Gasket part number N3C1 15 173 Water Pump Kit part number N3Z1 15 S20 NOTE To Determine The Correc
129. 3 Apply a non permanent thread locking compound Loctite 242 or equivalent to the three 3 mounting screws and install the mirror See Fig 1 4 Verify the repair DOOR MIRROR VIBRATION APPLY TREAD LOCK TO SCREWS CAT S NO 020 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 35AM Apply Non Permanent Thread Locking Agent To the Mounting Screws 94F58789 Fig 1 Mounting Door Mirror WARRANTY INFORMATION Applies To Verified Customer Complaints On Vehicles Covered Under Normal Warranty Refer To The SRT Microfiche For Warranty Term Information Warranty Type A Symptom Code 83 Damage Code 9G Part Number Main Cause FDO1 76 120 Right Door 76 180 Left Door Quantity 0 Operation Number XX0739RX Labor Hours 0 3 both sides NOTE in the PNMC designates the applicable color code END OF ARTICLE DOOR MIRROR VIBRATION REPAIR MT 0495 08 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 36AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN DOOR MIRROR VIBRATION Model s 1993 95 Mazda RX 7 Category Mazda Tips Bulletin No MT 0495 08 Date April 1995 SERVICE INFORMATION If the left or right door mirrors shake or vibrate under normal driving conditions or on
130. 626 MX 6 NEW ENGINE AVAILABILITY PARTS TABLE A T 3 BP05 02 300 8ABA 02 31 3 3 0 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 BP06 02 300 8ABA 02 3 3 3 0 ARAAAAAAAAAAAAAAAAAAA 0 3 3 AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 0 BP01 02 300 7 8ABB 02 3 NE RP Pa 3 Year Model Engine P N 3 3 U Gasket 3 3 Remarks 3 1981 82 626 3 3 HE41 02 300 8AU z02 3 3 3 0 3 1983 85 626 3 3 FE01 02 300 8AG 02 3 ARAAAAAAAAAAAAAAAAAAA 0 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1986 87 626 w w www 3 NON TURBO 3 TURBO 3
131. Be sure to use the hoses clips and gaskets designated in this procedure and do not reuse the removed parts When installing the hoses be sure to check their locations in accordance with the instruction and install them correctly PROCEDURE B REPLACEMENT OF FUEL HOSE KIT AND THROTTLE HOSE KIT To be performed on ALL customer sold vehicles NOTE Throttle Hose Kit part number N3A1 13 S60 and Filler Cap Kit 6 part number N371 15 S10B must be ordered separately and are not included in Fuel Hose Kit Start the engine Remove the circuit opening relay After th ngine stalls crank the engine for 15 20 seconds to purge the injectors Turn the ignition switch off Install the circuit opening relay See Fig 32 Circuit Opening Relay Fig 32 Finding the Circuit Opening Relay Disconnect the negative terminal from the battery RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 25 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM NOTE Record all preset stations on the vehicle s audio system prior to disconnecting the battery terminal 7 Drain coolant and retain in an appropriate container 8 Remove the bolts from the duty solenoid and the pressure chamber Tightening Torque 70 100 kgf cm 61 86 in lbf See Fig 33 Duty Solenoid Remove Bolts fr
132. Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM R amp R one sides P0209ARX 0 5 hrs R amp R both sides P0214BRX 0 6 hrs late s R amp R one side Plate Plate Plate Plate D FLE Plat Rear Brakes Disc Pl D Plate Plate PO208ARX 0 4 s R amp R bot PO208BRX 0 6 s Machine P0214AMX 0 7 5 achine hrs h sides hrs on vehicl NES nrs A M P0214BMX 1 2 R amp R one sides P0209ARX 0 5 R amp R both sides B PO214BRX 0 9 late s R amp R one PO208ARX 0 4 s R amp R bot PO208BRX 0 6 s Machine PO214AMX 0 7 s achine P02 MX 1 2 e nrs nrs side hrs h sides hrs on vehicle on vehicl one sides both sides one sides nrs nrs P0209ARX 0 3 R amp R both sides PO214BRX 0 5 A M B R amp R one sides A t B te s R amp R one P0208ARX 0 5 P0208ARX 0 4 s R amp R bot P0208CRX 0 9 PO208CRX 0 6 s Machine P0214AMX 0 7 s Machine P0214BMX 1 2 ce nrs nrs side hrs hrs h sides hrs hrs on vehic on vehicle 1993 94 1995 1993 94 1995 both sides one sides hrs on vehic hrs R amp R one sides P0209ARX 0 4 P0209ARX 0 3 R amp R both sides PO214BRX 0 5
133. ED AARAA o al fs Tree vor H31SAS 10MINOO 1111 W31SAS TOULNOD ANIONS 8 WVHOVIC 7 oO eo N e e o Y Ov 9p ATE Sy fnb Ay O YQYNY2 03 381983131000 TOWLNDD NIYNIMSAOd 10 18 d d 5 21 8 NOTLI3S lt E 381983 370008 CE 99 NO1123 1 3 NOI123 1 t41 2 NOI123S z SE O NIVYLY3AOd 1338 CHILTAS NYAI HILIAS 31SN19 1 H 335 8418 L ON Mg LINN 1081N02 M31Y3H NOILVNIBKOD 1N3HAELSNI NOISSIMSNYBL an LL E 2 8 N011235 INOOH GY 04 8 tc oz 491 2 NOLL23 b 0N 2 0N a 62 62 1081502 VAT 61 18 oO 8315519 S1Y13H 4 8 NIVYLY3A0d LL lt 43 8 88 1N34DH1 SNT 1N11002 I Ez uosN3s 8 91 2 8011235 id QuYZvH Z EL 22 18 68 62 931500 04 1 Aye A s LNBHAYLSNL 91 2 FINK 5 MOSN3S HOSNIS 61 18 4011930 OE 3 1 38 59314 tn 1939 ma SEL 1304 SN183319 YLVO SNTNUYA am iS 998 83 1v3H W Xf 2271s Hg 14 zu ki gt D Er 1314 88 t3947 1 1 TA L SNESX ER Genk ux 5 2 A 243 4 88 41 3 41 D 3 D o B sz x 47 Lex ch yo 170 oO n 03 D D 5 3 84 1 91 87A c o 9 Z 5 lt en on Gre soe iini sm H a 2 A 8 o im Y z S G2 P 153 Z lt sae o3 LL o g 3819831310004 gt 1081N02 NIYBIUJAOd tc e O lt LL D 43 13 WH 3 i Wa 43 Pru 31 93 3
134. Fig 48 Installing New Rear Thrott ter Hose N3A1 13 681A Use New Clamps 8 Replace the throttle body water hose with a new one using two new clamps See Fig 49 Water hose N3A1 13 691A Clamps 99287 1400P 2 pcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 35 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 94C 59347 Install New Throttle Body Water Hose Using Two 2 New Clamps Fig 49 Installing New Throttle Body Water Hose N3A1 13 691A Use Two New Clamps 24 Removal of primary fuel distributor secondary fuel distributor and insulator See Fig 50 1 Loosen the four bolts 2 Loosen the connector bolt from the inlet of the secondary fuel distributor Bolt Fuel Connector 94A59329 Fig 50 Removal of Primary amp Secondary Fuel Distributor amp Insulator 25 Remove the fuel hose from the primary fuel distributor RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 36 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM See Fig 51 NOTE When turning the screw be careful not to break the heads of the screws F two because they are tight Be care
135. MazDa MAZDA CANADA INC WARRANTY TAG PART NO TROUBLE DESCRIPTION CUSTOMER COMMENTS R O NO VIN REPAIR DATE KILOMETERS DELIVERY DATE TYPE OF WARRANTY DEALER NAME amp ADDRESS 9999 94 5011 E F Rev 05 89 94C59313 Example of Warranty Tag Th defective unit must be shipped to the Quality Assurance Centre REMANUFACTURED TRANS CANADIAN DIAGNOSIS SHEET CAT J NO 95 02 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 18AM as specified in the enclosed revised Parts Merchandising Bulletin If a core unit is received without a properly completed Warranty Tag and or properly completed Automatic Transmission Diagnosis Information Sheet the core credit will not be processed for payment n The dealer will be advised of the situation by the Warranty Administration Department Once the missing information is faxed received by the Warranty Administration Department the core credit will be processed If the requested information is not received within 10 working days the core unit will be shipped back to the dealer freight collect Two copies of this Service Bulletin are being supplied to each dealer Please give the second copy to the Mazda Parts Manager NOTE Five copies of the Automatic Transmission Diagnosis Information Sheet
136. Remove the thermostat RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 23 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Install thermostat with new gasket NOTE Ensure that the jiggle pin is in the 12 00 o clock position See Fig 29 45 Install a new coolant level sensor and gasket See Fig 29 46 Install the thermostat cover NOTE Install water level sensor connector bracket 47 Connect the coolant level sensor 48 Install alternator bracket pulley and belt in reverse order of removal See Fig 25 49 Install new upper radiator hose 50 Install air cleaner and fresh air duct 51 After assembling parts follow the instructions below prior to replenishing coolant Measure the concentration of antifreeze in the removed coolant with a hydrometer If the concentration is more than 45 use the removed coolant to fill the system purge air from the system and fill the coolant reservoir to the F mark If the concentration is 45 or less add 100 anti freeze to the coolant system as specified in the table on the right Purge the system of air Use the original coolant to fill the reservoir to the F mark NOTE Coolant refers to the fluid drained from the vehicle Antifreeze refers to 1
137. WARRANTY CLAIM SUBMISSION Dealers submitting warranty claims must retain copies of the Battery Maintenance Record and the Battery Check Sheet The operation number listed below is used for Battery Inspection Charging and Testing This includes Battery Load Test Battery Replenishment Charging and Capacity Test Charging Test Dark Current Test HF 0X WARRANTY INFORMATION FOR BATTERY INSPECTION CHARGING AND TESTING Symptom Code Complete Actual Code Damage Code Complete Actual Code MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM Part Number Main Cause Complete Actual Part Number Operation Number G0501ACX Labor Hours 0 5 hrs Vehicles other than 929 0 6 hrs 929 Vehicles NOTE If a charging problem still exists after battery charging and or replacement follow the charging diagnostic procedures covered under operation number G0001 DX to identify the problem Basic diagnostic operations require separate punch flag time Hours shown on the SRT microfiche are the maximum allowable times BATTERY CHECK SHEET NOTE Attach this Check Sheet to the reverse side of Repair Order
138. 00805 3 3 3 ACT 3120 3540 4100 RARAARARAAAARARAARARAAAARAAAARAAAARAAAAAAAAARAAAAAAAAAAAAAAAAAAAA 3 Technical Chemical 3 SERCON 8000 M A MA MAH 3 Company 3 MV MAV H 9000 M A 3 MV MAH MAV H 9220 E HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM 9220 SOOOH with SR4000 or 4000A filter 5000A 5000AB 5000MB or 5000MBJ with 3 SRA000 4000A or 4000H filter AARAAAARAAAARARAAAARAAAARAAAARAAAARARAAAARAAAARAAAAAAAAAAAAAAAARA 3 3 3 w w w w w w w Toyota SPX Robinair I TOY 01380 TOY 01396 3 00002 01396 01 42 17400 3 3 17400TOYJ 17401TOYJ 17404TOYJ 3 Trane Division of RRPC 3 3 American Standard Inc 3 Van Steenburgh 3 JIV90 4 3 2 1 LV30 4 3 2 5 l 3 3 Engineering Lab Inc 3 CM 239 25 E
139. 1989 98 Mazda Models Category S Body Bulletin No 020 97 Date October 23 1997 NOTE This bulletin supersedes Technical Service Bulletin number Cat S 031 95 DESCRIPTION Prepare replacement bumpers for painting according to the instructions in this bulletin NOTE Service Managers are requested to distribute these instructions to body shop personnel PREPARATION PROCEDURE 1 Soak a terry cloth towel in isopropyl alcohol CAUTION Grease Wax remover that contains Naptha based solvent ex PPG DX 330 may remove the bumper s factory primer If this occurs the bumper will require primer application prior to painting 2 Clean the entire surface with the alcohol soaked towel 3 Allow bumper to air dry NOTE The bumper must be completely dry before painting 4 Remove any lint threads remaining on the bumper with compressed air 5 Paint the bumper according to the paint manufacturer s instructions NOTE See PAINTING PROCEDURE SAMPLE Body shops using other paint manufacturers should follow their bumper painting procedures SUPPLIES REQUIRED Terry Cloth Towel Available Locally PRE PAINTING PREPARATION FOR FRONT amp REAR BUMPERS CAT S NO 020 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM Isopropyl Alcohol Available Locally PPG Mu
140. 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 05AM Align Assembly Slightly Wiggle Connector Left and Right Then insert Straight 94F 59381 Fig 2 Correct Installation of Male Connectors This Position After Aligning Will Damage Push Straight Pins Until Connection 94G59382 Is Complete Fig 3 Installation of Male Connectors HARNESSES 1 DO NOT STRETCH harnesses to connect connectors 2 Route harnesses to provide slack in harness and no stress on connector Refer to Fig 4 Fig 4 AIR CONDITION MALFUNCTION HAZARD SWITCH CONTACTS CAT U NO 95 09 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 05AM Do Not Stress Harness Allow Slack When Lib MAT 94H59383 Correct Installation of Harness WARRANTY INFORMATION Applies to verified customer complaints on vehicles covered under normal warranty Refer to the SRT Microfiche for warranty term information Warranty Type A Symptom Code 60 Damage Code 9G Part Number Main Cause FD01 66 4 0 Quantity 1 Operation Number TO204XRX Labor Hours 0 3Hrs END OF ARTICLE DTC DIAGNOSTIC TROUBLE SHOOTING TIPS MT 0597 07 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Re
141. 94152272 Fig 1 Shift Select Spindle PARTS INFORMATION TABLE 7 Part Number y Description ARAAAAAAAAABAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAARAAAAAR 3 R503 17 550 Shift Select Spindle 7 W501 17 725B 3 5th Gear Synchronizer i 3 NOTE The part number of the spindle has not changed 3 3 Parts in your facing PDC are new Dealers with P spindles existing in inventory should check the 3 5TH GEAR SHIFTING NOISE NEW SHIFT SELECT SPIDLE CAT J NO 001 94 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 17AM gt 8pindle using the method Shown below AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU WARRANTY INFORMATION Applies to vehicl s covered under normal warranty Warranty Type A Symptom Code 82 Damage Code 24 Part Number Main Cause R503 17 550 Operation Number J0312XRX Labor Hours 4 8Hrs END
142. AARAARARAAAAAAAAAAAAARARAARARAAAARAAAAAAAAAAR 3 Fuel Gauge Front Caster 3 Indication Shown in degrees minutes 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Empty 3 3 degrees 05 to 5 degrees 05 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA L 4 3 3 degrees 10 to 5 degrees 10 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA x L 2 3 3 degrees 15 to 5 degrees 15 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 4 3 3 degrees 20 to 5 degrees 20 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Full 3 3 degrees 25 to 5 degrees 25 3 AAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 NOTE Specifications may differ between i models 2 3 Follow the operating procedures specified for the alignment equipment being used 4 Prior to measuring the current settings firmly push the vehicle bumper up and down to stabilize the vehicle s height END OF ARTICLE ALIGNMENT SPECIFICATIONS AND TOLERANCES INFORMATION CAT N NO 001 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 22AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ALIGNMENT SPECIFICATIONS Model 5 All Mazda Models except Navajo amp 1994 and on B Series vehicles Category
143. END OF ARTICLE SQUEALING SOUND FROM THE HOOD MODIFY RUBBER CUSHION CAT S NO 057 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 41AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SQUEAKING SOUND FROM THE HOOD Model 5 1993 Mazda RX 7 Category S Bulletin No 057 92 Date 12 15 92 AFFECTED VINS his bulletin applies to 1993 RX 7 models produced through July 2 992 and with a VIN of JM1FD33 P0208750 and lower eH This bulletin does not apply to 1993 RX 7 models with a VIN equal to or greater than JM1FD33 P0208751 and produced after July 2 1992 DESCRIPTION Some vehicles may experience a squealing sound from the hood when driving on normal road surfaces After July 2 1992 the hood was modified to eliminate this condition REPAIR PROCEDURE If the above condition occurs install a washer between the two cushion rubbers under the hood See Fig 1 MAGNIFIED VIEW Cushion Rubber FDY1 56 788 94F53996 Cushion Rubber Fig 1 Rubber Hood Cushion PARTS INFORMATION TABLE SQUEALING SOUND FROM THE HOOD MODIFY RUBBER CUSHION CAT S NO 057 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 41AM AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAR 3 Part Number De
144. FLUID CONDITION Burnt Particles Adjust Level Inspect Repair Wash Engine And Transmission Transmission Cooler Power Flush Inspect For Leaks Leaks Found YES Record Localion Of Leaks Is Vehicle Repaired Repair Use WSM YES Retum To Customer 94B54107 Seals Oil Pump Gaskets Service Manager Contacts the 800 If Necessary Write R O Technician Review R O Understand Complaint Road Test If Necessary ts AT Fluid In Good Condition YES Perform Pre Checks And Retrieve Codes Using The NGS Tester YES Repair Vehicle Per Self Diagnostic Function And Clear Code From Memory NO Is Vehicle Repaired YES Retum To Customer Call Hotline Can Trans Be Repaired At Dealer NO Fig 2 Automatic Transmission Diagnostic Flow Chart END OF ARTICLE AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW CHART t PRE CHECK PROCEDURES Review Repair History Check Engine Electrical System Performance Check For Non Factory Equipment Check Shift Linkage Adjustment Vehicles With Ford Components KOEO and KOER Tests Record Mechanical System Test and Line Pressure on Check Sheet Use Trans Complete A T Check Sheet Request Authorization Order Trans Replace Trans UNUSUAL ABNORMAL k NOISE DRIVEABILITY Visually inspect Fluid
145. For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM Brake Drum s Machin one side Labor Operation PO201AMX 0 8 hrs Brake Drum s Machine both sides Labor Operation PO201AMX 1 3 hrs Brake Shoe s R amp R one side Labor Operation PO204ARX 0 7 hrs Brake Shoe s R amp R both sides Labor Operation PO204BRX 1 0 hrs Navajo Rear Brakes Brake Drums s R amp R one side Labor Operation PO201ARX 0 5 hrs Rear Brakes Brake Drums s R amp R both sides Labor Operation PO201BRX 0 7 hrs Brake Drum s Machin one side Labor Operation PO201AMX 0 2 hrs Brake Drum s Machine both sides Labor Operation PO201AMX 0 4 hrs Brake Shoe s R amp R one side Labor Operation PO204XRX 1 0 hrs Brake Shoe s R amp R both sides Labor Operation PO204XRX 1 0 hrs 94 B Series and later Rear Brakes Brake Drums s R amp R one side Labor Operation PO201ARX 0 4 hrs Rear Brakes Brake Drums s R amp R both sides Labor Operation PO201BRX 0 6 hrs Brake Drum s Machin one side Labor Operation PO201AMX 0 2 hrs Brake Drum s Machine both sides Labor Operation PO201AMX 0 4 hrs Brake Shoe s R amp R one side Labor Operation P0204XRX 1 0 hrs Brake Shoe
146. If leaks occur repair as necessary LEFT ENGINE MOUNT INTERFERES WITH OIL PAN BOLT CAT B NO 008 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 35AM Apply Silicone Sealer To This Area From The Bottom Remove Only This Oil Pan Bolt NOTE This Raised Area interferes With The Oil Pan Bolt Head 97154345 Fig 1 Oil Pan Bolt Location END OF ARTICLE MOTOR MOUNT HEAT SHIELDS NOISE MT 0394 10 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 35AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER MOTOR MOUNT HEAT SHIELDS RUB RUBBING OR GROANING NOISE Model 5 1993 Mazda RX 7 Category Mazda Tips Bulletin No MT 0394 10 Date March 1994 DESCRIPTION The heat shields for the engine motor mounts may rub the mount producing a rubbing or groaning noise from the lower front suspension area You hear the noise as you drive slowly over bumps or as you turn DO NOT replace the mounts control arm bushings or struts Instead inspect the heat shield s according to the Workshop Manual page D 19 part 3 If there is contact use a screw driver to care fully pry the heat shield s away from the point of contact If you still hear the noise refer to Service Bulletin R 004 93
147. L990 94 MPV 3 3 1990 92 RX7 3 NA4 3 1993 95 RX7 3 RB4 3 1990 92 626 MX6 3 8 3 1990 92 626 MX6 3 G4 3 1993 626 MX6 3 3 1993 96 626 MX6 3 GF4 3 1994 96 626 MX6 3 LA4 NA4 GF4 A EL 3 0L JE D Jatco 3 RWD ECAT 3 A EL 3 0L JED 3 Jatco 3 RWD ECAT 3 A EL 3 2 3L KJ 7 Jatco FWD ECAT 3 A EL 3 255L Kg Mazda FWD ECAT 3
148. NOTE A high majority of brake judder is due to DTV of the front rotors Customer complaints of brake judder are most often corrected by machining the front rotors only D Measure the remaining front rotor thickness and run out Determine if sufficient rotor material remains to allow machining Limit Stated minimum thickness for the model plus 0 8 mm E If machining can be achieved an on car brake lathe is recommended to ensure a precise rotor surface NOTE After machining rotor s with an on car brake lathe you must remove all metal cuttings particles from the ABS toothed ring the reluctor and the ABS sensor Failure to remove these particles will prevent proper function of the ABS system F If machining can not be achieved due to rotor thickness limitations the dealer should replace the rotor To ensure a successful repair run out and or DTV must be removed by on car machining even on new rotor s G Install the wheel in the same location relative to the hub as it was originally positioned BRAKE JUDDER REPAIR CANADIAN CAT P NO 94 06 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 24AM H Torque wheel lug nuts to the specifications in the service manual I Test drive the vehicle to confirm repair J If the brake judder is still felt correct
149. Refer to Fig 2 to Valve Actuator Operation identify components for Charge Control Improper damaged bent nicked or removed condition Carefully check the ollowing 3 3 3 Valve Actuator 3 3 3 Improperly connected 3 3 3 3 3 3 Charge Relief Valve Turbo A 3 3 3 3 3 3 3 Piping Bent 3 3 3 3 3 Control Actuator 3 3 3 3 3 3 3 3 3 3 3 3 A Nicked and Removed Hoses Turbo Pre Control Actuator in Fig 2 piping around area Less Removed hoses around area H MI hose for bent condition U w w QU w Repair or replace defective parts as necessary Fig SYSTEM SCHEMATIC PARTS IDENTIFICATION TABLE 2 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM SYSTEM SCHEMATIC B Negative Press Check Vaive Solenoid Valve Turbo Pre Control Solenoid Vaive Turbo Control Pressure 1 Chamber Solenoid Valve Wastegate Control Solenoid Valve Solenoid Valve White Charge Control Brown Turbo Control 98D51618 l Intake Syste
150. SERVICE TOOLS The WARRANTY INFORMATION Accu Tum mode The brake lathe wil Program at a substantial savings established will combine further details brochure on this brake a Special 8750 Tools Service On Car Brake When Lath Bulletin will is recommended by Mazda ll be available soon from MMA s National Accounts the national account is be released which lathe please However i call f you wish to receive a Accu Turn at 800 551 2228 Rear Wheel in warranty le for labor time from the Applies To Vehicles Covered Under Normal Warranty Warranty Type A Symptom Code 83 Damage Code 9B Part Number Main Cause 33 25 26 25 Rear of Vehicl Drive Only Operation Number P0113AMX 0 7 hrs Front One Side PO113BMX 1 2 hrs Front Both Sides PO214AMX 0 7 hrs Rear One Side P0214BMX 1 2 hrs Rear Both Sides NOTE 1 Unnecessary replacement of rotors will result claim denial 2 Brake pad replacement costs will not be warrantab brake judder repair 3 If an on car lathe is used apply the table above NOTE Warranty policy does not permit using an off car brake lathe after January 1 1995 The next issue of the SRT microfiche will be revised to show new labor times BRAKE DRUMS LABOR OPERATION TIME CODES 1993 1995 MODELS 626 MX 6 Labor Operatio Labor Op
151. SPARK PLUG COIL WIRE SET NO T 1 6 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 00AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SPARK PLUG COIL WIRE SET Model 5 All Mazda Models Through 1995 Category Parts Bulletin Bulletin No T 1 6 Date November 1 1990 Revised April 24 1995 DESCRIPTION A complete line of Mazda Spark Plug Wire Sets are available from your servicing PDC These high quality wire sets are manufactured for Mazda by NGK Each wire set includes the coil wire s and is attractivel for merchandising purposes The carton can be placed on a wall display The part number and model applications are clearly indicated on the front and on the end of the carton Each wire is numbered for easy installation and the instructions are printed on the back y packaged Complete wire sets cannot be used for new vehicle warranty Individual wires are available under the MC part numbers as indicated in the Parts Catalog Microfiche PARTS INFORMATION PART NUMBERS AND APPLICATIONS TABLE AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Year Model 3 NGK P N Mazda P N AAAAAKAAAAAKAKRAAAAKAAAAKAAAAKAAAAKAAKAAKAKAAAAKAAAAKAAAAARAAAAA 1971 74 RX 2 B RC ZE9 3 0000 18 091A AKAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAARAAAAAAAAAAAAAA 1972 78 RX 3
152. The glove box lamp may stay on when the glove box door is closed The lamp cover has been modified to prevent this condition If this condition exists replace the glove box lamp cover with the modified lamp cover according to the instructions listed below REPAIR PROCEDURE 1 Remove the glove box 2 Remove the two installation screws for the lamp assembly and remove the lamp cover 3 Install the modified lamp cover and glove box Glove Box Lid Remove 2 Installation Screws Remove Glove Switch Box Assembly Lamp Cover 94453165 Fig 1 Glove Box Assembly d cs RD cet UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAG 3 Part Number 3 Description 3 Quantity 3 GLOVE BOX LAMP STAYS ON NEW LAMP COVER CAT S NO 042 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 37AM 7 New 3 Old 7 2 1 3 FDO1 64 170A FDO1 64 170 Lamp Cover i 1 3
153. U 3 YES 3 3 UAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Turn The Headlights On For 3 3 15 Seconds To Remove Any 2 3 Surface Voltage Charge i i 3 3 YES 3 UAAAAAAAAAA Battery Voltage 12 4V 3 x 2 3 or Above 7 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 3 3 NO 3 Apply Test Load To 3 3 Quick Charge Battery 3 Battery Refer To 3 3 And Recheck Voltage 3 3 Chart Record Battery AAAAAAAAAAAAAAAAAAAAAAAU 3 Voltage After 15 3 YES AAAAAAAAAAAAAAAAAAAAAAAAAAAA i Seconds AAAAAAA Battery Voltage 12 4V 3 3 or Above AAAAAAAAAAAAAAAAAAAAAAAAAAAAAU AAAAAAAAAAAAAAAAAAAAAAAAAARAR Replace Battery 3 ww wiw MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM 3 AAAAAAAAAAAAAAAAAAAAAAAAAA NO UAAAAAAAAAAAAAAAAA 3 Is Voltage More Than Replace Battery gt Load Test Specification
154. pipe assembly is installed Connectors may appear to be in 2 place but not fully connected AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 3 3 3 3 3 3 3 3 No fast idle 3 Check the idle speed control valve connector for good connection 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 Excess fuel consumption Improper vacuum may result in faulty after recall repair 3 fuel regulator operation 3 work 3 Check fuel regulator vacuum hose 2 connection 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 3 3 Unusual air noise from If the Air Control Valve check valve center of engine just is not properly seated the ACV can off idle 3 not seat properly 3 3 Check that the ACV check valve is SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM w 3 properly installed 3 AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Cooling fan will not 3 If the cooling fan will not operate 3 3 3 3 3 operate 3 under any conditions during the fan 3 test 3 3 3 3 Check the wire harness ground 2 strap for proper connection
155. tc 8 7 usa 071 0 9 826 A 91 8 21 8 9 LL Q 21 18 Lt 18 4 1 182 0 8 62 18 82 18 L 18 92 18 ra 18 t2 18 31518 sine 3c IMYA ai 3 JAWA ayay 1N083 ME 18084 9NIHOLIAS E JAINA 010N3705 JAWA 010N310S A8Y0N0235 AuvOn033S AuvHT 84 189 tc de uy ins dt 010N310 3105 eendig 0123CNI 80123CNI 80123C8I Oo AMYONO23S v0h033 es 1804 5 331138 gly 11165 91 18 Li 18 91 18 1 18 LL 62 18 82 18 L2 i8 2 18 2 18 v2 18 z 18 83 3 wa 431 ual oda oi 83 83 ED 3 2 A a 8 8 A8 A 8 R O 8 91 8 nonas 278 A8 M8 1 8 91 6 11336 i 3 l 1843 3 31 U l 3 AYA3U NIYM 13 83 432 Av138 A B ava Ala A 8 ne 193 4 8 2 1 8 4 8 193 LL a amp Fuel Control System 1994 RX 7 ine Diagram Eng 98F51628 iring W 16 Fig Oo d e gt c oO E oz Oc 56 Ot J 555 NE OES NS acres g ESEN D gt o x N E GO os oN TEE m NN wami e z D 5 s lt E SS lt oos LL 9 amp D ES Q SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD 002 96 7X v66l O NnONS 3 00 N 3 INY10 3 8 11 9 8 91 B 335 38 NET 93 41 29 x 4tO 0803 H211AS NOILINSI 2 3 431270N NOISSIW3 1 4 1 1 N33A138 HUO123NNO2 1 28 243 80123NN02 32382
156. 010 93 Date 2 26 93 AFFECTED VINS This bulletin applies to vehicles with a VIN of JMIFD P0210513 or lower produced through November 30 1992 This bulletin does not apply to vehicles with a VIN equal to or greater than JMIFD P0210514 and produced after November 30 1992 DESCRIPTION On some vehicles noise ma be heard from the rear hatch hinges This noise is most evident when driving on rough roads or going over bumps fois Rear Hatch Hinge lt Replace w modified 27 part z Rear Hatch 93756423 F Fig 1 Modified Rear Hatch Hinge REPAIR PROCEDURE lf the above condition exist replace the rear hatch hinges with a modified part The modified part has been improved to eliminate the noise PARTS INFORMATION TABLE NOISE FROM THE REAR HATCH HINGE REPLACEMENT PARTS CAT S NO 010 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 38AM Part Number SE EL NRI i M o AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 62 2106 62108 Rear Hatch Hinge 2 AN
157. 14 Removal of Relief Air Hose amp Vacuum Tubes NOTE When reassembling replace the ACV gasket with a new one RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM Gasket N3A3 13 996 When reassembling be sure to insert the check valve in the step cut position of the intake manifold then attach the ACV Make sure that the wire harnesses of the solenoid valve will not touch the ACV 23 Move the vacuum pipe assembly toward the steering shaft side See Fig 15 d NOTE Loosen the thr bolts that attach the vacuum pipe to the ngine S letter C in Fig 15 Disconnect the coupler from the solenoid valve attached to the vacuum pipe Remove the vacuum tubes water hose and fuel hoses cutting the fuel hoses off where indicated by scissors in Fig 15 makes the work easier Do not remove hoses other than 1 14 Remove the hoses on the sides indicated by arrows shown in Fig 15 Be careful not to damage any pipes When removing the hoses do not use any spray type lubricant Move the vacuum pipe assembly toward direction D as shown rn Eug 5 When reassembling replace the hoses 1 2 3 4 5 6 7 8 10 and 11 with new ones RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 1
158. 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM Charging Testing Charging testing is not covered under vehicle warranty and is considered part of normal dealer processing responsibility Boost charging is covered within 48 hours of vehicle delivery NOTE This operation will require completion of the Battery Check Sheet Wholesale Delivery Inspection Battery Replacement requires DCSM authorization Additionally the Battery Check Sheet and Battery Check Tag must be completed and attached to the repair order If the documentation is not attached to the repair order the claim will be subject to debit After Retail Delivery Replacement is covered under normal warranty if the battery is judged defective after charging and diagnosing the battery according to the procedures in this bulletin The Battery Check Sheet must be completed and attached to the repair order If the documents are not attached to the repair order the claim will be subject to debit After Retail Delivery Replacement is covered under normal warranty if the battery is judged defective after charging and diagnosing the battery according to the procedure in this bulletin The Battery Check Sheet must be completed and attached to the repair order If the documentation is not attached to the repair order the claim will be subject to debit
159. 221 226 F Engine coolant temperature above 108 C 226 F Engine coolant temperature Engine coolant temperature sensor mal n n PO 210660 A Cop Cooling fan Cooling fan eration relay No 1 relay No 2 Cooling fan Cooling fan Cooling fan relay No 3 relay No 4 operation OFF OFF OFF Engine cool ant tempera ture over 108 C 226 F after ignition switch is tumed OFF Engme cool _ ant tempera ture becomes lower than 108 C 226 F after igni tion switch is tumed OFF to OFF If the cooling fan will From VIN JM1 FD331 PO 210661 and verify that the cooling fan operates approximate he ignition switch is turned to ON n operates tor by using a jumper wire ON ON 1769 F to ON for 15 seconds or longer Turn the ignition switch to ON and Wait for approximately 150 Turn the ignition switch to ON 00 150 seconds not operate inspect the Battery positive voltage Fan control signal Engine coolant temperature signal Ground y o1 owing SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM 7 Turn the ignition switch to OFF 8 Verify that the coo
160. 46 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 37 Remove and discard the radiator cap from the sure tank and replace it with a Rad cap NOTE If the new one Included in Kit vehicle has no coolant leakag xperienced and no coolant leakage at present proceed to PROCEDURE E PROCEDURE D REPLACEMENT OF THE WATER PUMP KIT NOTE Procedure D is continued from procedure E Water Pump Kit Part number N3Z1 15 320 Thermostat Gasket must be ordered separately and is not included in the Fuel Hose Parts Kit 38 Remove the bolts from the fresh air duct and remove the fresh air duct See Fig 66 Remove the rubber hoses from the air cleaner Remove the air cleaner installation bolts 39 Remove th upper radiator hose See Fig 66 LT 94E59349 Fig 66 Fresh Air Duct Bolts amp Upper Radiator Hose 10 Remove th alternator installation nuts from the alternator RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 47 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM adjuster bracket to remove the tension control bolt 41 Remove the water pump pulley and alternator belt See Fig 67 Loosen the four bolts from the water
161. 6 9 x 1 78 3 LB51 6 3 5 3 AAAAAAAARAAAAAAAAAAAAARAAKRAAAAAAAARAAAAAAAAAAMAAAAAAAAAAAARAAAMAAA 3 D 3 L2mm 10 8 x 1 78 3 LB54 6 3 3 3 AAAAAAAKAANANARAAAANAAAAAAAAKAAAAAAAAAARAAWAAARARAARARARAAAAAAAAAAR 3 F 3 16mm 14 0x 1 78 3 LB56 6 3 2 3 AAKAKKANWAAAKAKAKAKRAAAAAKRAKANAKAKAKAKAAAAAAAAANAKAAAAKAAKAKKAKAANKANU NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 2 for O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM Fig 2 1989 94 323 Protege O Ring Identification 1992 96 MX 3 O RING DESCRIPTION TABLE 3 Pipe O Ring 3 Part Numbers Quantity 3 Ring Size gt Size D X T 3 and per 3 Code 3 3 3 Kit Numbers 3 Vehicle 3 A 8mm 3 6 9 x 1 18 3 LB51 61 JIX d 5 3
162. 87 Damage Code 99 Part Number Main Cause RX 7 FDO1 57 630E 00 FDO1 57 630E 17 FDO1 57 630E 33 MX 5 57 6305 00 57 6305 17 57 630D 88 Operation Number XX0619RX Labor Hours 0 3Hrs END OF ARTICLE SEAT BELT EXTENDER DESCRIPTION ORDERING INFO CAT S NO 032 96 ARTICLE BEGINNING Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC TECHNICAL SERVICE BULLETIN SEAT BELT EXTENDERS Model 5 1991 94 1994 1994 1993 1988 1992 1993 1995 97 1995 97 1990 97 95 89 95 97 97 1989 97 Mazda Mazda Mazda Mazda Mazda Mazda Mazda Mazda Mazda Mazda Mazda Category S Body Bulletin No 032 96 Date December 26 Saturday August 25 2001 07 41AM Navajo B Series Protege MX 3 MX 5 Miata RX 7 929 929 626 MX 6 Millenia MPV 1996 NOTE This bulletin supersedes Technical Service Bulletin number 032 96 dat DESCRIPTION d September 23 1996 A fully extended seat belt that will not reach across the lap of the vehicle occupant can b lengthened by 8 9 or 12 inches using a seat belt extender Seat belt ext xtender S Fig facing PDC The foll extender is delivered nders are now available through your lowing Warning Label is affixed to the seat belt The proper usage and s
163. A AAARARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 31990 91 929 SOHC JE39 02 300 8AJA 02 310 3 3 3 3 0L A A AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA DOHC JE27 02 300 8AJB 02 310 3 ARAAAAAAAARAARARAAAARARAARARAARARAAAAAARAAAAAAAAAAAAAAAAAAAAARARAAAAAC 1992 93 929 DOHC NONE NONE Use Short Block 3 3 0L 3 4 JE48 02 200B ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 31994 929 3 0L DOHC JE74 02 300A 8AH3 02 310 3 3 U 2 EET 3 Year Model 3 Engine P N 3 Gasket P N Remarks 3 ALL RX 7 i 3 See Parts 3 3 3 Bulletin R 6 3 3 3 3 3 MANA Rebuilt 3 3 3 Rotary Engines U A
164. A EL 3 8 BP i Mazda FWD ECAT 3 AAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAA A EL 8 BPD 3 Mazda 3 FWD ECAT 3 AAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAA 1995 96 Protege 3 FA4 3 3 1990 91 Protege 3 1990 93 Miata 3 NA4 3 1994 96 Miata 3 NC4 3 1992 96 MX3 3 FA4 3 1990 94 323 3 FA4 3 1990 93 B2200 3 NA4 3 990 93 B2600 3 NA4 3 3 GAAX EL 3 8 A EL 3 Mazda 3 FWD ECAT 3 AARAARAARAAARAARAARAAARAARAARAAARAARA AAA A FWD 4WD ECAT 3 AAAAAAAAAAAAAAAAAAAAAAAAA AAA AAR AAAA AAA AAR A AAA AAA AAAAAAA AAR AAAAAAAAA BP 3 A HL 3 6 B6 3 Mazda 3 Jatco 3 RWD HAT 3 A EL 3 8 BPD 7 Jatco 7 RWD ECAT 3
165. August 25 2001 06 55AM If your vehicle is presented to an authorized dealer on an agreed upon service date and the remedy is not provided within a reasonable time or the remedy does not correct the defect or noncompliance please contact Mazda Service Center at 1 800 222 5500 Also contact the National Highway Traffic Safety Administration s auto safety hotline at 1 800 424 9393 ADDITIONAL INFORMATION The National Highway Traffic Safety Administration operates Monday through Friday from 8 00 AM to 4 00 PM Eastern Time For more information call 800 424 9393 or 202 366 0123 For the hearing impaired call 800 424 9153 END OF ARTICLE RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM ARTICLE BEGINNING RECALL CAMPAIGN RX 7 FUEL LEAKAGE RECALL CAMPAIGN NUMBER 60504 Model s 1993 94 Mazda RX 7 Canadian Category RC Recall Bulletin No 95 01 Date May 1995 DESCRIPTION If an RX 7 is driven under severe conditions such as high speed and uphill driving and the engine is turned off the temperature of the engine compartment rises because of the residual engine heat to the extent that it may cause premature deterioration of the fuel hoses elasticity Repetitive operation may lead to a reduction in the sealing performance of the f
166. Automatic tr All Mazda models with Automatic Transmission K 05 Automatic Transaxle 005 98 April 22 1998 ansmission A T oil cooler lines must be power flushed completely bef ore an overhauled or replacement A T is installed One of the causes transmission c of repeat A T failures is an internal automatic cooler This r uid ATF restriction at the inlet side of the oil estriction is usually caused by an accumulation of metal particles and mesh type baf c Ec debris from a previous A T failure on the internal e of the oil cooler Power flushing will remove the restriction by flushing to en CAUTION Repe flus ollowed by forward a typical ATF cooler back flushing the cooler lines f sure full ATF flow See Fig at repairs caused by improper or lack of cooler line hing WILL NOT be covered under warranty REPAIR PROCEDURE c Before power c quickly dislod before forward ushing MUST begin with back flushing ushing inspect the hoses lines and clamps Power followed by forward flushing to c ge the restriction If back ushing is not performed flushing the restriction could further reduce the ATF flow through t will not b f he internal mesh type baffle of the cooler and flushing fective or pos
167. Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM Remove the accelerator cable and the cruise cable See Fig 35 94H59318 36 Removing Accelerator Cable amp Cruise Cable arrows harnesses only Harnesses Vacuum EGR Vacuum ACV Vacuum Tubes Purge Hose Doub e Thrott Doub e Thrott Hoses Water Hose Hose Hose e Contro e Contro Raise the extension manifold and disconnect the following vacuum tubes and hoses from the side indicated by the See Figs 37 38 amp 39 Inlet Air Temperature Sensor AB Solenoid ISC Valve Hose Actuator Hose RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 28 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM Pressure Sensor Ee dra lt gt Sy av ane r c4 hose A N WS ACV Vacuum 5 ev Hose EGR Vacuum Hose 94159319 Fig 37 EGR Vacuum Hose amp ACV Vacuum Hose Fig 38 Hoses to Disconnect 94C59321 X XA a Fig 39 Switch to Disconnect 17 Remove th xtension manifold and throttle body RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 29 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company L
168. DMX 1 ne sides LARX 0 4 B 1 th sides RX 0 6 nrs nrs nrs both sides AIR PUMP FAILURE DUE TO NON GENUINE AIR FILTERS CAT F NO 006 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 32AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN AIR PUMP FAILURE DUE TO INSTALLATION OF NON GENUINE AIR CLEANERS Models 1993 95 Mazda RX 7 Category F Bulletin No 006 95 Date 4 5 95 DESCRIPTION Installing non genuine air cleaners may lead to air pump failure Unlike the original design non genuine air cleaners draw heated engine compartment air into the air pump See Fig 1 This air increases pump temperature which may result in lubrication loss and bearing failure Customers should be informed that the vehicle warranty prohibits alteration of the emission control system as well as other components Recommend that the customer have the original air cleaner installed to prevent non warrantable component failure Non Genuine 94A57372 Fig 1 Exploded View of Installed Non Genuine Air Cleaner END OF ARTICLE CRACKS IN TURBOCHARGER MANIFOLD INFORMATION MT 0495 07 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 34AM ARTICLE BEGINNING TECHNICAL SERVICE
169. LLC Saturday August 25 2001 07 24AM 3 Gears 3 CMH CMH 3 CMH 3 CMH 3 CMH 3 Shafts 3 CMH CMH CMH 3 CMH 3 CMH 3 7 Bearings 3 CMH CMH d CMH CMH CMH 5 Seal Rings 3 CMH 3 CMH 3 CMH 3 CMH 3 CMH 3 3 O rings 3 CMH CMH B CMH 3 CMH 3 CMH 3 Bands 3 CMH 3 CMH CMH 3 CMH 3 CMH 3 Drums 3 CMH CMH E CMH CMH CMH
170. NYS 9NI1002 10 26 ns 30 9 118 3010 1 208 t0123NN02 HOLIASOWN3HI p 32342 U31YA 90 28 0 28 80 28 8 Y L0 28 2 0N L ON 9 NOTLI3S pi ae er Eo E I em 4 8 i Dx SAT3002 antago LINN 13 SISONOYIO HILIASONUHL ain 3 8 90 28 50 28 69 6 n 3 3 EL 2H3 4 8 4 8 M 4 8 9 24189 31 10 4 ON 283 ta19 1 Yon 555 149771 2431 283 243 282 3384 cay sch 1 8 8 5 teu coi 0 28 0 x 0 1 5 4 81 8 1236 co 28 2 0N 91 8 N011235 44 033 AV138 NY3 49138 Nyd AY138 NY4 LIN 1931 9 1009 9 1002 ONT 1003 ivia NYE ox 9 1009 O QNO3 yiv HOLIAS NOLLINDI 3134 YSI a COO Ags D 0 ac 19 AUBLLYE 41871 1Y 23 70D WJLSAS NY4 ONI71009 2 4 WvHoVI ONIHIM 7 98D51626 Diagram Coolant Fan System 1993 RX 7 Wiring 13 Fig COOLING FAN CONTROL SYSTEM 1994 RX 7 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM DESCRIPTION To improve idle smoothness and engine reliability the cooling fan control system controls the electrical fan speed by ECM This system consists of the cooling fan cooling fan relays cooling f
171. Saturday August 25 2001 06 56AM Radiator hose Included in Kit 54 Install air cleaner and fresh air duct PROCEDURE E COOLING SYSTEM CHECK AFFIXING CAMPAIGN LABELS NOTE Procedure E is continued from procedure D 55 After assembling parts follow the instructions below prior to replenishing coolant Measure the concentration of antifreeze in the removed coolant with a hydrometer Tf the concentration is more than 45 use the removed coolant to fill the system purge air from the system and fill the coolant reservoir to the F mark Tf the concentration is 45 or less add 100 anti freeze to the coolant system as specified in the ANTI FREEZE CONCENTRATION TABLE Purge the system of air Use the original coolant to fill the reservoir to the F mark NOTE Coolant refers to the fluid drained from the vehicle Anti Freeze refers to 100 new coolant ANTI FREEZE CONCENTRATION TABLE ll UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Concentration Of Amount of Anti Freeze 3 Anti Freeze 3 To Be Added 3 3 0 55 3 4 4L 3 3 5 10 3 4 1L 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 10 15 3 3 8L 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 15 20 3 3 5T 3
172. See Fig 35 NOTE Disconnect the hoses at the locations indicated by the arrows shown in Fig 35 only 14 Remove the harnesses from the extension manifold See Fig 35 Remove these four parts referring to Step 16 Pressure Sensoc PCV Hose 1 Double Throttle Control Hose 2 Purge Control Hos ACV Vacuum Hose 3 Vacuum Chamber EGR Vacuum Hose Hose 94G59317 Fig 35 Removing Hoses amp Harnesses From the Extension Manifold NOTE Use the above illustration to determine the hose location 15 Fig 16 RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 27 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Remove the accelerator cable and the cruise cable See Fig 35 94H59318 36 Removing Accelerator Cable amp Cruise Cable arrows harnesses only Harnesses Vacuum Tubes EGR Vacuum Hose ACV Vacuum Hose Purge Hose Doub e Thrott Doub e Thrott Hoses Water Hose e Contro e Contro Raise the extension manifold and disconnect the following vacuum tubes and hoses from the side indicated by the See Figs 37 38 amp 39 Inlet Air Temperature Sensor AB Solenoid ISC Valve Hose L Actuator Hose RX 7 FUEL L
173. Speedometer sensor meter to EC AT control unit e Speedometer resistance e Throttle sensor connector e Wiring from throttle sensor to EC AT control unit e Throttle sensor resistance e Pulse generator connector e Wiring from pulse genera tor to EC AT control unit e Pulse generator resistance e ATF thermosensor connector ATF ther Open or short circuit Wiring from ATF thermosen 56 of ATF thermosensor sor to EC AT control unit Yes mosensor sd or wiring e ATF thermosensor resis tance e Wiring from engine control unit to EC AT control unit e EC AT control unit e Engine control unit Speed sensor 2 Speedometer sensor Open or short circuit of throttle sensor or wiring Throttle sensor Yes Pulse generator No input signal from pulse generator Open or short circuit of reduce torque signal slip lockup Signal wiring and or torque reduced signal wiring Open or short circuit of atmospheric pressure sensor wiring Reduce torque Signal Slip 57 lockup signal lorque reduced signal Yes Atmospheric e Wiring from engine control unit to EC AT control unit Yes e Engine control unit 58 e Solenoid valve connector e Wiring from solenoid valve to EC AT control unit eSolenoid valve resistance e Wiring from dropping resis tor to EC AT control unit Only N
174. Terminals C D B applied 3 Continuity 3 3 B not applied 3 No continuity 3 U NOTE Battery positive voltage 4 If not as specified replace the cooling fan relay For additional wiring schematic information see Figs 12 and 13 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM Type Body Side Type Type Front L Cae ea ie A 7g Z 2 e ci i 9 asassdussqhssd4sss VA 98B51624 Fig 11 Terminals A and B n ESX TUOS N T EE gt N aNE os Fssfs o Oo 2 2a gt lt 52 L 95 65 Copyright 1998 Mitchell Repair Information Company LLC SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 1 XY 8661 0 Z 56 9 passa CHER x31 c O31 33 893 RJ UH2LIAS 13 L 331139 O3 384 SSYdA8 H Y 180d WJ
175. This is the second time the battery has failed The previous battery was purchased 10 months ago WARRANTY INFORMATION TABLE EXAMPLE 3 Claim Submission Dealer Reimbursement 3 AAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAMAAAANAAARAAAAAAAAAAABARARAAAA Warranty type K 3 Warranty labor 3 rate 50 00 hr 3 Symptom code 20 3 3 3 Damage code 81 3 Vendor code KN999 3 3 3 Part number 3 5 3 main cause 5555 95 BATT 3 3 Quantity 1 must enter 3 3 quantity of one 3 3 3 Pro Rate 100 3 15 70 handling charges 3 3 3 only 3 3 Related part s 0 wet battery acid 3 i 3 is not required 3 3 Labor operation labor is not available 3 Labor Hours for over the counter 3 3 parts warranty 3 3 3 Total 3 3 3 reimbursement 15 70 2 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 CUSTOMER S RESPONSIBILITY 00 00 U Free battery provided by Interstate Distributor Example 4 A 1993 Navajo battery failed This is the second time the battery failed The first battery failed 20 months ago WARRANTY INFORMATION TABLE EXAMP
176. White Industries Model 01050 3 3 Refrigerant Recovery Sys Inc K Whit Tools Inc 3 P O Box 360298 3 100 Visionary Way 3 3 3 3 3 3 3 Tampa Florida 33673 Fishers IN 46038 800 327 9142 800 849 6830 3 R 12 Recover Recycle Machine NAPA TEMP ATC 1000 3 3 3 3 3 Justice Glass amp Supply Co Murray 2445 Third Avenue Div of Moog Automotive Inc Huntington West Va 25703 P O Box 7224 800 624 3420 St Louis MO 63177 314 385 3400 3 3 3 3 3 3 3 3 3 3 3 3 3 CFC SAV R with Robinair 3 Everco A9989 with Robinair 3 3 retrofit kit 17217 3 retrofit kits 17217 and 17216 3 LSK Inc 3 Everco Industries 3 3 McPherson KS 67460 3 P O Box 7224 3 3 St Louis MO 63177 3 3 3 314 385 3400 3 3 Robinair 17200 With retrofit 3 MODEL K 3330 3 3 Kits 17216 and 17217 17500 7 James Kamm Technologi
177. amp REPLACEMENT PROCEDURE If you encounter a complaint that the hold light starts flashing while the vehicle is running and torque reduction control fail code is 57 follow this procedure 1 Are any short circuits damaged wiring or bad coupler contacts present If yes repair circuit If no proceed to Step 2 2 Replace EC AT control unit with a modified unit PARTS INFORMATION TABLE 3 Part Number 1 Description 3 Interchangeability 3 New Old 3 N AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 N3A2 18 9EIB N3A2 18 9E1 EC AT Control Unit 3 New Old U 3 WARRANTY INFORMATION HOLD INDICATOR LIGHT FLASHES REPLACE CONTROL UNIT CAT K NO 012 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 22AM Applies to Vehicles Covered Under Warranty Warr
178. iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 44AM NOTE The card test can only be used to evaluate the A pillar sealing contact Use the following WHITE GREASE TEST to evaluate the rest of the weather strip WHITE GREASE TEST 1 Roll down windows and adequately cover all interior surfaces to prevent contact with grease 2 Thoroughly and evenly spray the sheet metal surface of the body that seals against the weather strip on the door NOTE Tt is recommended that you use KAR Products 78620 Multi purpose white greas aerosol spray or equivalent DO NOT spray the weather strip 3 Using only the door handle very gently close the door This will prevent over slam which could result in an inaccurate reading 4 Open the door and measure the width of the grease pattern that is left along the length of the weather strip check for any unevenness in width See Fig 2 a If 4 mm or more sealing contact is adequate if door closing effort is acceptable Clean grease from vehicle b If 3 mm or less sealing contact is insufficient Clean grease from vehicle and proceed to DOOR ADJUSTMENT DOOR ADJUSTMENT The door should be adjusted to obtain the proper seal compression while maintaining proper door alignment The hinges control the in out location of the door at the front as well as overall tip or tilt of the door when vi
179. item 1 N G O K Continue to Check Sheet item 4 O K N G Completed Refer to Check Sheet item 4 step 2 Recheck Check Sheet 94F50588 item 1 Diagnostic Flow Chart CHECK SHEET Heater concern Item 1 Measuring Vent Outlet Air Temperature Ls Place transmission in park or place manual transmission in neutral and set the parking brake Start the engine and let idle until th ngine reaches normal operating temperatures Determine nature of complaint a problem or b improper usage Instruct customer on proper system usage 5 NOT Ite A Ly 2 3 4 5 NOT B Ls 24 HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Adjust the climate controls to the following settings EUBCULODI quyun kian usa Bi level Temperature Visas Max hot Fan speed 2 Recirculate fresh Fresh Raise th ngine speed to 2000 rpm and hold for ten minutes Measure the vent outlet air temperature E The thermostat will cycle after th ngine has reached operating temperatures Measure outlet air temperature several times over a ten minute period to attain the high temperature reading thermostat closed m 2 Air Leakage Interior Components Remove the lower kick panel on
180. later B Series vehicles DESCRIPTION The following information is designed to assist dealers in determining when to replace the receiver drier when replacing other A C components Do not replace the receiver drier unless the following criteria have been met RECEIVER DRIER REPLACEMENT CRITERIA Replace the receiver drier when the A C system has been ruptured and ALL system pressure is lost Receiver drier will require replacement if the compressor oil becomes discolored or foreign substances become visible Refer to the flow chart in this article NOTE Refer to section U of the workshop manual for additional receiver drier diagnostic procedures If an A C component has failed extract the compressor oil from the failed part and inspect the oil according to the procedure described in the following flow chart Follow the procedure to determine if the receiver drier requires replacement as a precaution AAAAAAAAAAAAAAAAAAAAAAAAAR 3 1 Inspect Oil for I 3 Discoloration 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAAA Dark Gray or AAAAAA Replace 3 3 3 Black 3 3 Receiver Drier 3 3 AAAAAAAAAAAAAAAU AAAAAAAAAAAAAAAAAU AAAAAAAAAAAA AAAAAAAAAAAAR RECEIVER DRIER REPLACEMENT CRITERIA INFORMATION CAT U NO 001 95 Article Text p 2 1993 Mazda RX7
181. the dealer warranty claim for labor and handling charges 95 BATT as the PNMC with a quantity of one the dealer 15 70 for handling c harges see example 12 Replacement Batteries which fail after 12 months If the dealer installs the battery the dealer should submit a warranty claim for the pro rated battery only NOTE Pro rate applies to replacement batteries replaced after 12 months Replacement Battery 48 Month Pro rate Chart II AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Months Customer s Dealer 3 In Use Responsibility Claims I 3 AAAAAA AAAAAAAKAA 3 2 0 12 0 Labor Only 3 3 13 24 50 plus labor 50 3 gt 25 36 75 plus labor 25 I U Reimbursement is based on Dealer Net Price DNP plus 30 on 1993 and earlier models and DNP plus 40 on 1994 and later models GENERAL INFORMATION WARRANTY BULLETIN MAZDA BATTERY WARRANTY CAT G NO 1 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 47PM applies to all warranty battery claims TOWING Towing is covered for warrantable repairs during the Mazda New Vehicle Limited 36 Month 50 000 Mi
182. 1 8 2931 A78 81 8 NO11235 381983 300 WYLNOD NIYHIH3A0d uly V 318 1 4138 NYJ 24a 97 C ON 4 003 LLL 283 3 A 8 n31u 8 ROE C2W3 1 8 831478 e 283 MN313W VEL p 90 ac MOOK 1081N02 4 LNY1002 60 26 1 213 0 14312 0N NOISSTW3 1 3 INOU3 N33A139 YOLIINNOD 243 U0123NNO2 33283 90 28 0 3 1410 2 0N YOLORK N 4 1 1002 2W3 243 A 8 9 b 0N 3 NYS 1NY1003 243 243 a 1 t KILTASOWBJHL U31Y LO 28 243 HOLOW 4 1NY1002 143 NY 3 2 ON AY13U 4 1NY1002 20 28 3 131071 28 3 n00W 710H1N02 11136 4 1005 243 b Z S69 pospoy 11 68 4 UO10H NY3 1 1003 90 28 3 L ON YOLOW 2 50 8 AY138 NYJ I1NY3002 10 28 31 8 1335 C3NT9N3 NOI133S YOLI3NNOD NTT v1vO 99 1335 83141 IAHI LINN NIVYLB3AOJ 3 U31Y3H 1 0N AY338 NV4 1 003 1243 I 1 01 28 vo ec 1 283 63 i ee ae 1 H Yo un aa 3 417 21 28 20 vor NY3 9N17002 Y09 3 A478 3 AVE A8U311Y8 W31SAS NV3 INV1009 2 8 MYHOVIG ONIHIM 7 98051628 Diagram Coolant Fan System 1994 RX 7 iring W Ty Fig END OF ARTICLE SPEEDOMETER REPLACEMENT PROCEDURE CAT AD NO 003 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com C
183. 1 870 00 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 J008 99X08R 1993 RX 7 3 1 270 00 3 1 870 00 REVISED ROTORY ENGINE PRICING CAT RF NO 95 24 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM END OF ARTICLE RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM ARTICLE BEGINNING RECALL CAMPAIGN RX 7 FUEL LEAKAGE RECALL CAMPAIGN NUMBER 60504 Model s 1993 94 Mazda RX 7 Canadian Category RC Recall Bulletin No 95 01 Date May 1995 DESCRIPTION If an RX 7 is driven under severe conditions such as high speed and uphill driving and the engine is turned off the temperature of the engine compartment rises because of the residual engine heat to the extent that it may cause premature deterioration of the fuel hoses elasticity Repetitive operation may lead to a reduction in the sealing performance of the fuel hoses and in rare cases engin c
184. 11 Service Cod Circuit Diagram SERVICE CODE 62 DIAGNOSTIC TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Service Code No 62 3 Solenoid valve Overrunning Clutch 3 WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 18 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM Step Inspection 3 1 3 Are there any poor 3 3 connections at solenoid 3 valve and EC AT control 3 3 unit connectors Connect a circuit tester to terminals 10 and ground as shown in Fig 12 Is output voltage of solenoid valve overrunning clutch at EC AT control unit OK Acceptable Voltages Battery voltage D range throttle valve closed Below 1 volt Except D range throttle valve open w w iw iw 3 Action 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Yes Repair or Replace connector 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 3 No 7 Go to next step 2 3 Yes Check wiring and go to 3 3 3 Step 5 3 3 3
185. 18 l 18 91 18 S 1 18z2R 62 18 82 18 Le 18 92 18 52 18 rz 10 t2 18 is auo T EU IMYA BAA BAYA BATA ONIHILIAS BATA 3A1YA 010N3105 JAYA 010N310S AYYONOI3S AUVON093S AuvMIUd 84 Q10N3105 55 418 MIY 0108310S 0103105 80123CNI MOLDICNI 4O193CNI 80123C8I uly SSYdA8 SSYd18 393 A YONOD3S 184 z 331138 115 8 1804 gly 11145 21 18 Li 18 91 18 62 18 16 92 18 c2 18 v2 18 CAT 13 TD 13 a 43 o mn A M o tua A a 8 8 A8 A 8 R O 8 91 8 nonas 278 A8 M8 1 8 91 86 3 l 831 LED 31 Ww lon 138 NI YM l 13 3 33 138 NIVW ava Ara A 8 A 8 Ms 746 153 4 8 1 8 4 8 193 H31SAS 10MINOO 13 nd W31SAS TO081N03 ANIONS 8 WvHovid 7 amp Fuel Control System 1994 RX 7 ine Diagram Eng 98F51628 iring W 16 Fig QR gt lt e KR Do 28 P lt SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 For www iluvmyrx7 com Oo ir zm gt oO 5 zb Ot ac o e So e gt co D lt 25 o g5 0 bed o Oo 7X v66l O NnONS 3 00 N 3 INY10 3 8 11 9 8 91 B 335 38 NET 93 41 29 x 4tO 0803 H211AS NOILINSI 2 3 431270N NOISSIW3 1 4 1 1 N33A138 HUO123NNO2 1 28 243 80123NN02 32382 80 28 C2n3
186. 2 3 5 Kohms 3 3 E ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 4 3 Disconnect pulse generator Yes Check wiring and connectors 3 5 3 connector 3 from EC AT control unit to 3 Is resistance of pulse 3 pulse generator 3 3 3 generator OK 3 3 If OK go to next step 3 3 Terminal Resistance 3 3 If not OK repair wiring E 3 3 AAAAKAAKAAAAAAAAAAAAAAAAAA 3 3 and or connector 5 3 A B 3 2 2 3 5 Kohms 3 B C 3 infinity 3 No Replace pulse generator 3 j 7 A C infinity 3 3 5 3 Disconnect negative 3 Yes Replace EC AT control unit 3 3 3 battery cable for at least 3 3 20 seconds AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Connect battery cable and No Intermittent poor connection 3 recheck for service cod 3 3 Check for cause 3 Is service code displayed 3 B U Fig SERVI WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC
187. 2 331738 SSYdAB Ul LEIS 113 JANYA 010N310S 62 18 3 OION310S 92 18 3 GIONZTOS 42 18 3 010N310S 92 18 JANYA 010 3105 62 18 JANYA 010N3108 b2 18 JAVA 3 05 C2 18 u0SN3S0HB3H 1304 22 19 LE SD 843 VOSN3S 3 HILIAS 5 4 12 18 Gate qs pats v jun MEN U X MEO ie 32 32 52 18 ox LI XE eect HR YOVNY277 6 1 10 2377 1 un 33 10 14 21 8 NO1123S D t 053 tye 9 NOIL23S 4 3 NOLLD3S 4t 3 1235 2 8 NOI1235 s N01123 H31IAS 934078 HOLTAS 8319013 NYA HOLTAS 4 H N011339 83 8 2 8 N011235 UON Md LINN 30MINOQ H3 V3M NOIIYNIGXO2 LN3MNYISHI OWH3Hl 31 LINN a ion 3 8 88 51 2 N011228 ZO qj 2 Co 62 7 T 1 18 M31903 3 NA 9 OSN3S D 0 d aus 4 2 1v3H OKUIHL A9 8 0 9 Wh HOLIAS 3 1 9 3n3 S d n NO113359 61 18 135 ONINHYA 22 18 aina tiranti SISON9YIO 11 0 gon W3 1 88 12 18 1 243 3 ex anus an VA 8 9 Vi EEJ ia VA 10 2H3 4 48 551 t Yo 2 N011236 4 un 41 rcx 4 d eer to 11 93 Hartas 02078 Le 41770 bu N Lex ies ii Md 01 8 u 8 UOLIBIHNI gt V 19 TET pu L N0112351 1 Y NOLLD39 Tacx PI ET OT AZ 13 VK L0 X 0 qi visi nm a _ lt r HOLTAS g A ni 1070 Wak a9 193 4 8 2031 NI u31uviS Wa IWD ua 31 13 83 3 31 wa 3 43 wn 8 1 0 1 1 0 5 usa
188. 3 A 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Chec k for cause 3 3 U EC AT CONTROL UNIT Code 64 Circuit Diagram DROPPNG RESISTOR Fig 14 Servic SERVICE CODE 65 DIAGNOSTIC TA BLE 94455434 3 Servic Code No 65 3 Solenoid valve Lockup Control 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 23 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM 3 Step Inspection 3 Action 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1 Are there any poor Yes Repair or Replace connector 3 3 connections at solenoid 3 3 3 3 valve and EC AT control
189. 3 3 3 3 3 No 3 Go to next step 3 3 w w www iw w w www iw ww www w 3 Disconnect 16 pin EC AT 3 control unit connector 3 Is resistance between 1D 3 terminal and ground OK 3 A 5 3 3 3 3 3 Resistance 20 40 ohms 4 Disconnect solenoid connector Is resistance between ground and terminal D of solenoid valve overrunning clutch OK Resistance 20 40 ohms w w www t ww w Disconnect negative battery cable for at least 20 seconds Connect battery cable and recheck for service cod Is service code displayed w w www w aaa is 3 Yes Go to Step 5 3 3 3 3 No 3 Go to next step P 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Yes Check wiring and connectors 3 3 from EC AT control unit to 3 solenoid valve overrunning 3 clutch 3 If OK go to next step 3 Tf not OK repair wiring 3 and or connector 3 3No Replace solenoid valve 3 3 overrunning clutch E w w w w w w www w 3 ARAAAAAAAAAAAAAA
190. 3 RC ZE9 3 0000 18 091A AKAAAAAAAAAAAAAAABAAAAAAAAAARAAAAAABAAAAAAAARAAAAAAAAAAAAAA 1974 78 RX 4 3 RC ZE9 3 0000 18 091A ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 1976 78 Cosmo 3 RC ZE9 3 0000 18 091A ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1974 77 Repu 3 RC ZE9 3 0000 18 091A AKAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAARAAAAAAAAAAAAAA 1975 77 808 1600CC 3 RC ZE92 3 0000 18 092A AKAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAARAAAAAAAAAAAAAA 1976 77 808 1300CC 3 RC ZE92 3 0000 18 092A ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 1977 80 GLC 3 RC ZE92 3 0000 18 092A ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 1981 83 GLC Wagon 3 RC ZE92 3 0000 18 092A PARTS BULLETIN SPARK PLUG COIL WIRE SET NO T 1 6 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 00AM 1972 74 808 PRIT NET 972 74 B 1977 78 1979 84 B 600 800 3 3 3 RC ZP RC ZP
191. 3 Resin 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAU WARRANTY INFORMATION Applies To Verified Customer Complaints On Vehicles Covered Under Normal Warranty Refer To The SRT Microfiche For Warranty Term Information Warranty Type A Symptom Code D5 Damage Code AA Part Number Main Cause 0000 88 5067 Quantity 0 Operation Number XX0777RX Labor Hours 0 3 Hrs END OF ARTICLE SEAT BELT EXTENDERS DESCRIPTION ORDERING INFO CAT S NO 005 98 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 43PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SEAT BELT EXTENDERS Model 5 1989 98 Mazda MPV 1995 99 Mazda Protege 1994 95 Mazda MX 3 1994 97 Mazda Miata 1999 Mazda Miata 1993 97 Mazda 626 MX 6 1998 99 Mazda 626 1993 95 Mazda RX 7 1988 89 Mazda 929 1992 95 Mazda 929 1995 99 Mazda Millenia 1991 94 Mazda Navajo 1994 98 Mazda B Series Category S 08 Body Bulletin No 005 98 Date August 5 1998 NOTE This bulletin supersedes Technical Service Bulletin number 005 98 dated April 22 1998 The Parts Information section has been corrected and revised to include 1999 models DESCRIPTION If a fully extended seat belt will not reach across the lap of the vehicle occupant a seat belt extender may be available which can lengthened a seat belt by 8 9 or 12 inches Refer to the PARTS INFORMATION for
192. 5 Cost 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 Ol d 3 New 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Harness Adapter 49F0 18 902 3 49TO 18 902 3 457 71 N 3 3 See Benefit Below 3 U ANNOUNCEMENT OS SST UPDATE PROGRAM 001 CAT ST NO 001 94 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 21PM PURPOSE OF PROGRAM The purpose of this program is to offer your dealer an opportunity to have the old 49F0 18 902 harness adapter updated to the new 49T0 18 902 harness adapter specifications The update includes the relabeling if the harness adapter with the new part number BENEFIT Your dealer s cost for this update is 50 00 as opposed to purchasing the new harness adapter for 457 71 The result is a savings s of 407 71 to your dealer PROGRAM IMPLEMENTATION 1 Your Mazda Regional Office has an update harness adapter available to loan to you during the implementation of this program Therefore in the event your dealer has a need for the new harness adapter for a critical repair and you do not have one available contact your regional of lice They can loan an updated harness adapter to
193. 86100 7 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 3 3 Chrysler SPX 3 OT 17350 OT 17400 OT 17700 3 Robinair 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Classic Tool 3 FBR 11 3 1 Design Inc 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Cornwell 3 RA 17350C RA 17400 RA 17500B 3 A SPX Robinair 3 RA 17700 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Diavia SPX Robinair 3 17705 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 D W Myers Enterprises AM 6000 MR 1991 A MR 1991 R 3 3 Inc 3 ME 1991 A 3 3 Dowmar Solvent 2 DR12R 3 3 Recovery Systems Inc 3 Draf Industries 3 1400 3 Enspeco Inc 3 RMS 3112 3
194. 9 5V and over Other Models After restoring the standard voltage value measure the fuel pump kiz pressure Max If pressure is not to specification replace the fuel pump If no trouble is found with the fuel pump and the problem still exists contact the Technical Hotline for assistance FUEL PUMP CHECK SHEET Dealer Name Technician Number Vehicle Year Model M T A T VIN Repair Date _ Mileage Repair Order Number 1 Customer Complaint Was the customer s complaint verified Yes No Reason for replacement Fuel Pump Did Not Operate Yes No Insufficient Fuel Pressure yes No Maximum Fuel Pressure PSI Factory Specification ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM According to Service Bulletin instructions Category No According to DSM or Hot Line Authorization Authorization Other Technician s Signature Date NOTE Attach the check sheet to the repair order If requested to return the failed air flow meter to Mazda attach a copy of the check sheet and repair order CHARGING SYSTEM OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER RARARARAAARAA A Diagnostics AAAAA
195. ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 20 25 3 3 1L 3 3 25 30 3 2 7L 3 AKAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAABAAAAA 3 30 35 3 2 2L 3 AKAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAABAAAAA 3 35 40 3 6L 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 40 45 3 1 0L 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 52 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM tration Use Hydrometer To Measure Concentration AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU Flow hole in tank and close the overt from the surge 72 56 Remove the cap the surge tank neck with tape AE See Fig SENSN q SSP OSS cover overflow hole 94D59355 Fig 72 Cover Overflow Hole 57 Install the radiator pressure tester on surge tank 58 Apply 15 psi See Fig 73 94E59356 Install radiator tester and apply 15psi Verify that pressure holds Fig 73 Radiator Pressure Tester Application 59 Verify that pressure holds RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 53 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM NOTE If the radia
196. Aberdeen Maryland 21005 5201 410 278 4099 Approval Date 8 12 92 Yellow Freight System Inc 10990 Roe Avenue P O Box 7270 Overland Park Kansas 66207 913 345 3000 Approval Date 8 12 92 END OF ARTICLE INSPECTION PROCEDURE FOR TEST LEAD OF NGS TESTER CAT ST NO 006 98 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 08AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN INSPECTION PROCEDURE FOR TEST LEAD OF NGS TESTER Model 5 All Mazda Models Category ST Service Tool Bulletin No 006 98 Date September 30 1998 DESCRIPTION The NGS test lead connectors may become loose or corroded causing incorrect readings Before using the ohm meter function of the NGS tester for diagnosing electrical circuits check for excessive resistance in the test leads and connectors and repair them if necessary NOTE Two types of connectors screw and solder are used on the NGS
197. CANADIAN Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM NOTE Do not remove the vacuum tube from the solenoid 94F59324 Fig 11 Three Way Solenoid Nut to be Removed 20 Remove the oil filler pipe See Fig 12 Tightening torque 70 100 kgf cm 61 86 in lbf ww Y W 94G59325 Fig 12 Oil Filler Pipe Identification 21 Remove the ignition coil assembly Remove the four nuts shown in Fig 13 Tightening torque of the nuts for reassembly Tightening Torque 70 100 kgf cm 61 86 in lbf RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM lue 4 L ey E ra TAS amie ELT 94H59326 Fig 13 Four Nuts Holding the Ignition Coil Assembly 22 ACV Removal 1 Disconnect the couplers from each solenoid valve in the ACV R in Fig 14 2 Remove the relief air hose See 3 Remove the ACV Re tightening torque of the nuts Tightening Torque 70 100 kgf cm 61 86 in lbf Remove the vacuum tubes from the inlet manifold See A in Fig 14 Replace the vacuum tubes with new ones Vacuum tube 99351 04095 x 4 pcs 94159327 Fig
198. CAT AD 003 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 45PM SPEEDOMETER REPLACEMENT Mileage Before Replacement Date Replaced Dealer Code Complete Information and Install On Driver s Side B Pillar SPEEDOMETER REPLACEMENT RECORD Speedometer replaced on with Dealer Name Dealer Signature After the speedometer is replaced total mileage should be determined by adding the mileage listed here to the current mileage shown on the speedometer installed Speedometer Replacement Label amp Record Identification END OF ARTICLE WARRANTY BULLETIN MAZDA BATTERY WARRANTY CAT G NO 1 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 47PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN MAZDA BATTERY WARRANTY Model 5 All Mazda Vehicles Category G Engine Electrical Bulletin No 1 Date 6 16 95 DESCRIPTION The Owner s Warranty Information booklet provided with each vehicle specifies the Original Equipment Battery warranty applicable to that model and model year Additional repair information is available in Mazda Service Bulletin publications Mazda batteries are covered by I Original Factory Equipment Battery Warranty II Replacement Battery W
199. Charging System Diagnostics Alternator and Battery Check Sheet SECTION 5 Warranty Inf Refer to the described in ormation appropriate service information for symptoms not this bulletin If further reference is required contact the Technical Hotline in your area ECU OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Diagnostics UU 2 5 2 RA RARRARA AT AARRAARRRAARRAU MMA 3 UARARARARAAAAA UAAAAAAAAAAAAAAAAY 7 Results AA No Trouble A Contact Region Found Hot Line 3 AAAAAAAAAAAAAAAAAU gt Trouble Found i 3 3 3 AAAAAAAAAAAAAAAA 3 Complete 3 3 Hot Line ue 3 Check Sheet AAAAAAAAAAAAAAA Instruction 7 3 Order Part Authorized AAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAU Replacement 3 3 3 Auth No Required AAAAAAAAAAAU Review 3 Receive Parts Diagnostics 3 3 Return Repl Part 3 3 With Check Sheet 3 3 To Your Servicing 3 3 PDC d 3 3 Warranty Claim 3 3 Application ECU AIR F
200. Check continuity of the relay TERMINAL CONTINUITY TABLE Operation 3 A Type Terminals D E 3 3 B Type Terminals C D B applied 3 Continuity 2 3 B not applied 3 No continuity U 3 NOTE B Battery positive voltage 4 If not as specified replace the cooling fan relay For additional wiring schematic information see Figs 16 and 17 t Z 589 D9SIABM Lj D a ast ave en La 8 931 3 CE 43 3 BATA ONTHOLIAS 43 DAIWA SSYd18 3 JAWA 3A1YA OION310S OTON3108 JAWA 010N3105 O10N370S 893 62 18 YY AuYvQNO235 02 19 WIY A vON0J16 L2 18 OIONI30S 284 92 18 SSYdAB 1804 2 18 331138 2 18 55 416 IY LITdS C2 8 HOSNISDHHIHI 7304 22 18 e l 125 43 R3 W3 3 UOSN35 84 HOSN3S 8 38 AUYQNO23S CINOU3 AYYONOI3S 8738 iuvHIBd 1N083 AUVHIUd 3unss3Hd ONIU331S 12 19 8 1Y3H 61 18 40123CNI 81 16 80133CNI 1 t8 WO123CNI 91 18 WOI23CNI 1 18
201. Comment Code 24 Damage Code 9M Part Number Main Cause R523 17 260A Quantity 1 1ST AND 2ND GEAR HARD TO SHIFT IMPROVED CLUTCH HUB CAT J NO 002 94 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 17AM Operation Number J0304BRX Labor Hours 7 2Hrs END OF ARTICLE 5TH GEAR SHIFTING NOISE NEW SHIFT SELECT SPIDLE CAT J NO 001 94 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 17AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN 5th GEAR SHIFTING NOISE Model 5 1993 RX 7 Vehicles with a VIN of JMIFD332 P0100001 through JMIFD332 P0210508 NOTE The asterisk in the VIN range can be any number 0 through 9 or X Category J Bulletin No 001 94 Date 1 7 94 Revised 1 27 94 DESCRIPTION If grinding occurs when shifting to 5th gear a 5th gear synchronizer ring damaged by mis shifting may be the cause To correct this concern the shift select spindle has been modified to increase accuracy of the shift pattern REPAIR PROCEDURES 1 Verify complaint 2 Replace the shift select spindle and 5th gear synchronizer ring 3 Inspect related parts for damage Replace as necessary Compress Spindle And Record Spring Force Old Part 6 7 0 7 kg New Part 8 9 0 7 kg
202. Conv 1993 95 Mazda RX 7 Category T Body Electrical System Bulletin No 007 97 Date April 25 1997 DESCRIPTION If you repair a vehicle in which the driver s side and or passenger ision damaged components side air bag deployed due to coll Diagnostic Module in addition to ensure the system is completely determine which system is instal ed in the vehicle DIAGNOSTIC MODULE INFORMATION TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 3 SAS Unit I Diagnostic Module 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Model 3 Year 3 Model 3 Year 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 MPV 3 1996 97 MPV 1993 95 7 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA x 626 MX 6 1995 97 3 626 MX 6 y 4993 94 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA MX 5 Miata 1995 97 MX 5 Miata 1990 94 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Protege 3 1995 97 3 RX 7 Conv 1988 91 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Millenia 1995 97 3 RX 7 1993 95 2 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 QUNM C OPERE 3 3 3 MX 3 3 1994 95 CAUTION Never attempt to repair the air bag System wiring always replace any 3 damaged wiring 2 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAA
203. Fitting 2 Reverse Lines And Flush Again Starting At The Cooler IN Line Fit ting NOTE Refer to the workshop manual for cooler location fittings on A4LD 4R44E and LA4A EL transmissions 95152604 Fig 4 Automatic Transmission Flushing Procedure WARRANTY INFORMATION Applicable warranty information will be included in the 1996 SRT microfiche AUTOMATIC TRANSMISSION DIAGNOSTIC SHEET ECAT AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Dealer Code R O Date Your Name Phone 1 VEHICLE INFORMATION VIN Mileage Transmission Unit Original Unit Reman Unit Replaced New Unit Retail Date Date of first repair Was the vehicle towed in No Yes Has the A T been previously repaired or replaced __ No __ Yes If Yes when What Are there any aftermarket parts installed Alarm Phone ETC No Yes If Yes Product Name X AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 19 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM CUSTOMER CONCERN Test drive vehicle _ No __ Yes Problem duplicated _ No __ Yes Symptom s Choose all that apply __ No movement __ Shift shock __ Clutch slippage __ Noise Whine Clunk __ Othe
204. For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 09AM Golden Brown Light 3 3 Brown Transparent or 3 Yellowish Gray 3 AAAAAAAKAAAAAAAAAAAAAAAAAAAU 3 2 Inspect Oil for x 3 Contamination 3 AAKAAAAAAAAAAAAAAAAAAAAAAAAAU 3 Contamination 3 Replace 3 AAAAAAAAAAAAAAAAA Present Part AAAA Receiver Drier 3 3 3 3 3 icles of Metal AAAAAAAAAAAAAAAAAU or O Ring 7 AAAAAAAAAAAAAAAAAU 0 No Obvious Contamination AAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAA AAAAAAAAAAAAR Do Not Replace the 3 3 Receiver Drier Continue 3 To Use Original ARAAAAAAAAAAAAAAAAAAAAAAAAAU CAUTION Before charging always evacuate the A C system thoroughly to remove air and moisture Use a vacuum pump to evacuate the system Hold vacuum at 29 inches 740mm Hg for 5 10 minutes END OF ARTICLE USE OF A C TRACER DYE SERVICE INFO CAT U NO 008 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 10AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN USE OF A C TRACER DYE Model All Mazd
205. Front Brakes Disc Plate s Machine on vehicl both sides Labor Operation PO113BMX 1 2 hrs Front Brakes Pad s R amp R one sides Labor Operation PO104ARX 0 4 hrs Front Brakes Pad s R amp R both sides Labor Operation PO104BRX 0 5 hrs RX 7 Front Brakes Disc Plate s R amp R one side Labor Operation P0102ARX 0 3 hrs Front Brakes Disc Plate s R amp R both side Labor Operation PO208CRX 0 5 hrs Front Brakes Disc Plate s Machine on vehicl one sides Labor Operation P0113AMX 0 7 hrs Front Brakes Disc Plate s Machine on vehicl both sides Labor Operation PO113BMX 1 2 hrs Front Brakes Pad s R amp R one sides Labor Operation PO104ARX 0 3 hrs Front Brakes Pad s R amp R both sides Labor Operation PO104BRX 0 4 hrs 5 Front Brakes Disc Plate s R amp R one side Labor Operation P0102ARX 0 5 hrs Front Brakes Disc Plate s R amp R both side Labor Operation P0208CRX 0 6 hrs Front Brakes Disc Plate s Machine on vehicl one sides Labor Operation P0113AMX 0 7 hrs Front Brakes Disc Plate s Machine on vehicl both sides Labor Operation P0113BMX 1 2 hrs Front Brakes Pad s R amp R one sides VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM Labor Operatio n Front Brakes Pad s MPV Fro Fro F
206. Holding the Ignition Coil Assembly 1 Disconnect the couplers from each solenoid valve in the ACV R 2 Remov t 3 Remove t Remov Tighteni t n n relief air hose See E in Fig 14 he ACV Re tightening torque of the nuts ng Torque 70 100 kgf cm 61 86 in 1lbf vacuum tubes from the inlet manifold See A in Vacuum t Fig 14 Replace the vacuum tubes with new ones ube 99351 04095 x 4 pcs 94159327 14 Removal of Relief Air Hose amp Vacuum Tubes E When reassembling replace the ACV gasket with a new one RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Gasket N3A3 13 996 When reassembling be sure to insert the check valve in the step cut position of the intake manifold then attach the ACV Make sure that the wire harnesses of the solenoid valve will not touch the ACV 23 Move the vacuum pipe assembly toward the steering shaft side See Fig 15 1 Loosen the thr bolts that attach the vacuum pipe to the ngine S letter C in Fig 15 2 Disconnect the coupler from the solenoid valve attached to the vacuum pipe 3 Remove the vacuum tubes water hose and fuel hoses cutting the fuel hoses off where indicated by scissors
207. INFORMATION TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 New P N 3 Old P N 3 Description Qty w Interchangeability HESITATION WHILE DRIVING CHECK ENGINE GROUND STRAP CAT F NO 005 97 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 00AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAA 3 FDO2 67 E70 3 FD01 67 E70A Earth Wire 3 1 A 3 3 NOTE Interchangeability A The new part can be used in place of the old part but the old part CAN NOT be used in place 3 3 of the new part WARRANTY INFORMATION Applies to verified customer complaints on vehicles covered under normal warranty Refer to the SRT microfiche for warranty Term Information Warranty Type A Symptom Code 08 Damage Code 9S Part Number Main Cause FD02 67 E70 Quantity 1 Operation Number XX899XRX Labor Hours 0 2 hrs END OF ARTICLE PARTS BULLETIN
208. J 38100 D 3 3 Kolpak Mfg Co 2 ZRM2000 AAAAARARARAARAAAAAAAAAAAAAAAARAAAAAAAAAAARAAABAAAAAAAAAAAARARAAAR 3 Lexus SPX Robinair 3 00002 01396 02 2 3 MAC Tools Inc 3 ACRRC 750 AC650 AC751 AC760 3 3 3 AC600 AC700 AC800 3 3 MAC Tools 3 AC17350C AC17400 AC17500B 3 3 Inc SPX Robinair 3 AC17700 AM 6000 2 Matco Tools Corp 3 ACRM120 ACRM3412 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA MEM C EU E M mE M A 3 Mastercool U S A Inc 7 Supervamp 62000 65000 65500
209. LLC Saturday August 25 2001 09 38AM 25 Remove the fuel hose from the primary fuel distributor See Fig 17 NOTE When turning the screw be careful not to break the heads of the screws F two because they are tight Be careful not to damage the pipe at the hose insertion location on the primary inlet side 94D59330 Fig 17 Removal of Hose from Primary Fuel Distributor 26 Install the modified fuel hose on the primary fuel distributor outlet side See Fig 18 NOTE When installing do not twist the O ring Replace the bolts with modified ones S letter G in Fig 18 Tightening Torque 25 36 kgf cm 22 31 in lbf Fuel Hose N3Z1 13 420 Bolt 99796 0510 x 2 pcs O ring Bolt B 94E59331 Fig 18 Installing Primary Fuel Distributor Outlet Modified Hose 27 1 Install the hose on the inlet side of the primary fuel distributor See Fig 19 Fuel hose N371 13 415 Submerge the hos nd with the white mark into adhesive RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Use adhesive specially prepared for this work NOTE Be careful not to use another adhesive
210. LONG BLOCK AVAILABILITY CAT B NO 004 94 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 36AM Se OT END OF ARTICLE PROPYLENE GLYCOL BASED COOLANT RECOMMENDATIONS CAT E NO 001 94 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 36AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PROPYLENE GLYCOL BASED COOLANT Model 5 All Mazda Models Category E Bulletin No 001 94 Date 10 21 94 AFFECTED MODELS All Mazda Vehicles DESCRIPTION Mazda does not recommend propylene glycol coolants Available information indicates the following characteristics regarding propylene glycol coolants Provides less heat transfer May not provide adequate corrosion protection to meet Mazda specifications Freezing temperature is 10 20 higher than ethylene glycol based coolants Mazda recommends ethylene glycol and water mixture Customer s with questions regarding coolant should be directed to the information in Section 7 of their owner s manual END OF ARTICLE RECALL CAMPAIGN 54407 COOL
211. Level Check Tester For LAdA EL For Paroles Diagnos And Isolate The Problem Use Quick Diagnostic Chart I From WSM Record Location Of Noise Internal YES Inspection Required NO Is Vehicle Repaired AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN AUTOMATIC TRANSMISSION REPAIR POLICY Model 5 All Mazda Models Category K Automatic Transmission Bulletin No 002 95 Issued Date August 10 1995 Revised Date October 31 1995 APPLICABLE MODELS VINS All Models Currently Under Warranty DESCRIPTION Policies of the Remanufactured Automatic Transmission Program have changed The contents in this bulletin describe the new and carryover features of this program as well as diagnostic applications Service Managers are requested to inform the necessary dealer personnel of these changes POLICY Adjustments repairs or component replacement for each transmission are limited to those items listed on the WARRANTY REPAIR PART GUIDE APPLICABLE Any vehicle within warranty that requires internal transmission repairs or rebuilding will be replaced with a MANA Remanufactured assembly NOTE MASH authorization is required pr
212. OF ARTICLE CLUTCH SLIPPAGE NEW CLUTCH DISC CAT H NO 001 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 17AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN Clutch Slippage D333 P0200001 D333 P0299999 1994 Mazda RX 7 with a VIN of JM1FD333 R0300001 through JMIFD333 R0300031 NOTE The asterisk in the VIN range can be any number 0 through 9 or X Model s 1993 Mazda RX 7 with a VIN of JM through JM F LF B LE Category HU Cluteh Bulletin No 001 93 Date 12 17 93 DESCRIPTION Customers with the following driving habits may experience clutch slippage or have premature clutch wear Starting from a stop in 2nd gear Hard acceleration deceleration cycles To improve the clutch for these conditions the facing material of the clutch disc has been changed These clutches have been used in production since October 8 1993 PARTS INFORMATION TABLE Part Number 3 Description Qty Interchangeability 3 3 3 3 New 7 Old 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
213. Pro A 3 3 Technologies Corp 5 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA P Fluoro Tech Inc FM3000 Certified by ETL Inc AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 MDI x 5150D 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 National Refrigeration E ULV63 j 3 Products Inc 2 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Power Manufacturing Inc 012B FRSPORT 01 Power R1 1 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Refrigerant Recovery 2 RC 1 A 3 Systems Inc AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 Refrigerant Recovery 3 PM3000 Certified by ETL Inc 3 3 Technologies Inc 7 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Refrigerant TX 200 Certified by ETL Inc 3 Technologies Inc 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 ROSSI Mini Suckerl Automotive Recovery 2 3 3 System RSI Part Number 600075 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 SPX Corporation i 17625A 3 3 Robinair Division 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Technical Chemical 3 SR5000MBJ SR 1000MBJ 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA E Watsco Components Inc 3 WC1S A 2 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
214. R both sides Labor Operation PO201BRX 0 6 hrs 1993 94 Labor Operation PO201BRX 0 3 hrs 1995 Brake Drum s Machin one side Labor Operation PO201AMX 0 3 hrs Brake Drum s Machine both sides Labor Operation P0201AMX 0 6 hrs MX 3 Re Re Br Br Br Br Brake Shoe s Labor Operation Labor Operation Brake Shoe s Labor Operation Labor Operation ar Brakes Brake ar Brakes Brake R amp R R amp R both si Labor Operation Labor Operation ake Drum s Machin on Labor Operation A ake Drum s Machine both Labor Operation A ake Shoe s R amp R one side Labor Operation A ake Shoe s R amp R both sid B Labor Operation IBRX 0 6 hrs P0204 P0204 Drums s P0201 Drums s P0201 one side ARX 0 5 hrs 1993 94 ARX 0 3 hrs 1995 des IBRX 0 8 hrs 1993 94 IBRX 0 5 hrs 1995 R amp R one side ARX 0 3 hrs R amp R both sides BRX 0 4 hrs P0201 93 B Series and earlier Re Re ar Brakes Brake ar Brakes Brake Labor Operation Labor Operation Drums s P0201 Drums s P0201 side MX 0 3 hrs LAMX 0 6 hrs IARX 0 4 hrs R amp R one side ARX 0 3 hrs R amp R both sides BRX 0 6 hrs VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Article Text p 5 1993 Mazda RX7
215. REPLACEMENT Model 5 1983 95 Mazda 626 Canadian 1988 95 Mazda 929 Canadian 1989 95 Mazda MX 6 MX 5 Miata Canadian 1995 Mazda Millenia Canadian Category T Body Electrical Bulletin No 95 06 Date April 1995 APPLICABLE MODELS VINS All vehicles equipped with a power antenna DESCRIPTION It is not necessary to replace th ntire antenna assembly if an antenna mast is damaged Follow the procedures below to replace only the mast portion of the assembly NOTE Bent or broken antenna masts i e damage not due to defects in material and workmanship are not covered under vehicle warranty REPAIR PROCEDURES 1 Remove the mounting nut with snap ring pliers or a spanner wrench 2 Hold the mast and have an assistant turn the radio ON If the antenna mast does not pop up use slip joint pliers to pull the mast up NOTE Holding the antenna mast is necessary to prevent paint damage 3 Remove any debris from the ground plate rubber bushing and mounting nut 4 Apply a small amount of lubricant to these pieces 5 Bend the plastic rack as shown in Fig 2 This will facilitate installation 6 Insert plastic rack into assembly until contact is made 7 Have an assistant turn the radio OFF to retract the antenna mast into the assembly Carefully guide the replacement mast into the POWER ANTENNA MAST REPLACEMENT CANADIAN CAT T NO 95 06 Article Text p 2
216. RPL AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Electrical solenoids RPL 3 RPL 3 RPL 3 RPL 3 AAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAA Electrical switches 3 RPL RPL 3 RPL 3 RPL 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Vehicle speed sensor e RPL RPL RPL AA AAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAA 3 Turbine speed sensor 3 RPL 3 3 Pulse generator 3 3 3 3 ATF thermo sensor 3 3 RPL 3 P MA RPL 3 Accumulators 3 3 3 7 AARAARARARAARARAAAAAARARAARARAARARAAAARARAAAARAAAAAARARAARA ADJ Adjust as needed per W M authorization not 3 3 required 3 RPL Repair or replace as needed per W M authorization 3 not required 3 CMH Call MASH Hotline for REMAN ASSEMBLY authorization 5 do not repair or replace component 3 1 Throttle cable not used on GF4A EL 3 2 Do not replace converter i 3 debris CALL MASH HOTLINE 3 3 3 3 A w oil pan is full of 3 2 3 accumul
217. Repair Information Company LLC Saturday August 25 2001 09 37AM RESULTING IN POSSIBLE INJURY B Connect the negative terminal to the battery C Connect the fuel pump terminal of the diagnostic connector to the ground terminal See Fig 19 D Turn ignition on for 30 seconds E Visually inspect for fuel leakage F Turn ignition off Record fuel pressur G After 5 minutes check fuel pressure If fuel pressure has dropped more than 2 8 psi after 5 minutes locate and repair fuel leaks Re test system following the above steps Install Fuel Pressure Gauge 98151662 Fig 18 Install Fuel Pressure Gag Diagnostic Connector To Ground Termina 98 151663 Fig 19 Diagnostic Connector to Ground Terminal RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 16 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Pressure 2 8 psi A 5 minutes 98A51664 Fig 20 Fuel Pressure Graph 27 Replace the throttle body water hose with a new one using two new clamps See Fig 21 Install New Throttle Body Water Hose Using Two 2 New Clamps 98B51665 Fig 21 Installing Throttle Body Water Hose 28 Install the following in reverse order of step 24 O2 sensor coupler on the ACV Pressure regulator cut valve vacuum h
218. SERVICE BULLETIN INSTALLATION OF TIRE CHAINS Model 5 All Mazda Models Category Q Tires Wheels Bulletin No 005 93 Date 6 3 93 DESCRIPTION Tire chains may scratch or chip aluminum wheels If chains are to be nstalled aluminum wheels should be changed to steel wheels Ju Please remind your customers of the following instructions when nstalling tire chains on their vehicle These recommendations are also explained in the vehicles owner s manual H 1 Investigate local regulations before using tire chains 2 Use only SAE Class S chains and make sure they fit the vehicle s tires 3 Follow the chain manufacturer s instructions 1 Remove the steel wheel covers if equipped to avoid scratches or damage 5 Front Wheel Drive Vehicle Secure the chains on the front tires as tightly as possible Retighten after one half mile of driving Rear Wheel Drive Vehicles Secure the chains to the rear wheels as tightly as possible Retighten after one half mile of driving CAUTION CHAINS MAY AFFECT VEHICLE HANDLING DO NOT GO FASTER THAN 30 MPH OR THE MANUFACTURER S RECOMMENDED SPEED WHICHEVER IS LOWER DRIVE CAREFULLY AND AVOID BUMPS HOLES AND SHARP TURNS AVOID LOCKED WHEEL BRAKING DO NOT USE CHAINS ON THE TEMPORARY TIRE THEY MAY DAMAGE THE VEHICLE AND THE TIR
219. SOHC 8L BKRSE BP01 18 0 1990 92 PROTEGE DOHC 8L BKR6E BP03 18 110 zs 1988 89 323 Turbo BCPR6E11 F220 18 110 1987 88 323 Wagon BPR5ES11 B601 18 110 _ 1987 92 B2200 BPR5ES 8914 18 110 8AB1 18 110A BP 1987 88 B2600 BPR6ES11 B601 18 110 1989 92 B2600i ZFR6A11 F201 18 110 x 1977 79 LC BP 6ES 025G 18 110 8AU1 18 110A BP 1977 79 LC BPRBES 1BG0 18 110 1977 80 LC BP5ES 0660 18 110 8AG1 18 110A BP 1977 85 LC BPR5ES 8G14 18 110 8AB1 18 110A BP SPARK PLUG CROSS REFERENCE CHART NO T 1 3 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 01AM 1979 80 LC Wagon BP5ES 0660 18 110 8AG1 18 110A BP 1980 83 LC Wagon BPR5ES 86G14 18 110 8AB1 18 110A BP 1986 D9432 747 808 BP7ES 0745 18 110 1976 808 1300 513 3710 18 110 1977 808 1300 BPR6ES 1690 18 110 _ 1972 77 808 1600 BP 6ES 0259 18 110 8AU1 18 110A BP 1972 76 B1600 BP 6ES 0259 18 110 B8A
220. Scientists worldwide believe that synthetic chemicals such as chlorofluorocarbons CFC s also know by the trade name Freon are rapidly destroying this layer of gas 10 to 30 miles above the earth s surface Ozone loss of 3 5 globally has already been recorded and is greatest over Antarctica where a seasonal ozone hole occurs Recent data strongly suggests that substantial losses may also develop over the North Pole exposing HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM parts of the U S to increasing levels of UV radiation Ozone loss in the atmosphere is likely to lead to an increase in skin cancer and cataracts and could weaken the human immune system Agriculture as well as plant and animal life may also be dramatically affected IMPACT OF MOTOR VEHICLE AIR CONDITIONERS One of the single largest uses of CFC s in the U S is as a refrigerant in automobile air conditioners CFC 12 in motor vehicles accounts for over 20 of all CFC use in this country Commonly released into the air when car or truck air conditioners are serviced CFC s rise to the stratosphere where they can remain active for up to 120 years Solar rays break these molecules apart releasing chlorine A single chlorine atom can destroy over one hu
221. Tips On Line or Call Hotline U U 3 YES 3 Return To Customer 3 U MAADES AUTOMATIC c n ON uu i wh E EE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Model Year 3 Trans Engine 3 MFG Applications AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAA 3 1990 91 929 3 NA4 3 1992 96 929 3 RAA 3 1995 96 Millenia S LJ4 3 1995 96 Millenia 7 GF4 3 1990 96 MPV 3 RAA 3 1990 96 MPV 3 RAA 3
222. Tips contents related to this recall General Driveability and Component Troubleshooting Tips Service Bulletin AD 002 96 Up dated reference pages for the applicable Wiring Diagrams NOTE Many driveability concerns occur from improperly performed repair procedures This information is provided to emphasize this point and give direction to prevent these concerns REPAIR PROCEDURE IMPORTANT Read this information thoroughly prior to performing recall repairs MAZDA TIPS Jan 1994 ed When performing the Fuel Line Recall on RX 7 Recall 60504 the following precautions and tips could save you a lot of extra time and eliminate unnecessary expenses Use extreme caution when removing the Fuel Pressure Regulator vacuum line The plastic solenoid pipe can be easily broken when removing the hose if caution is not exercised Secondary Fuel Rail Hose Replacement The fuel injector rails are very fragile and can be easily broken Remove the fuel distributor assemblies before you remove the Fuel Connector bolt Do not mount the fuel distributor in a vice Hold the distributor in your hand SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM and remove the Fuel Connector b
223. a metal panel example a door sash 2 Touch the static electricity ground pad equipped on the following vehicles MODELS EQUIPPED WITH STATIC GROUND PADS STATIC GROUNDING PAD TABLE UAAAAAAAAAAAAAAAAAAA 3 Model 7 Year s 3 ARAAAAARAAAAAAAAAAARAA 3 929 3 1992 94 ARAAAARAAAAAAAAAAARAA 3 626 MX 6 1992 94 7 ARAAAAAAAAAAAAAAAARAA 3 PROTEGE 1991 94 ARAAAAARAAAAAAAAAAARAA 3 MX 3 3 1992 94 3 AAAAAAKAAAAAAAAAAAAAU NOTE This feature has been eliminated from the 1995 model year END OF ARTICLE WHISTLING NOISE FROM THE WINDSHIELD MOLDING CAT S NO 049 92 ARTICLE BEGINNING TECHNICAL SERVICE BULL Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC ETIN Saturday August 25 2001 07 44AM WHISTLING NOISE FROM THE WINDSHIELD MOLDING Model 5 Category S Bulletin No 049 9 Date 10 5 AFFECTED VINS JM1FD331 P0207061 DESCRIPTION 2 92 May 31 1993 Mazda RX 7 1992 Some 1993 RX 7s may emit a whistling noise around the windshield area when being driven at high speeds This whistling noise is caused by air being pulled through the space between the molding and the windshiel d REPAIR PROCEDURE A repair seal foam kit has been established as a countermeasure If a whistling noise is encountered on a vehicle s produced on or before seal foam kit into the
224. alternator bearing NOTE Perform the above inspection with the vehicle headlights illuminated 3 Turn off the ignition and all accessories Connect a load tester VAT 40 or equivalent 4 Apply the load test referring to the LOAD TEST TABLE The final voltage must be above the standard minimum value shown in MINIMUM VOLTAGE TABLE LOAD TEST TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAR 3 Model 3 Test Load Amps ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 323 Prot 3 180 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 626 MX 6 3 174 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 929 3 180 3 3 195 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 MX 3 2 150 3 3 3 180 3 3 3 165 3 3 5 3 105 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 RX 7 3 180 3 ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 3 w w 3 MPV 2 Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM 165 3 L95 3 150 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 L95 3 A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAR A 3 B Series 3 150 3 3 3 195 3 3 3 95 3 AU MINIMUM VOLTAGE TABLE
225. applicable models and available lengths Fig 1 shows the Warning Label which is affixed to the seat belt extender The proper usage and safety related warnings listed on the extender must be explained to the customer when th xtender is delivered It is also the dealer s responsibility to explain the following Owners Manual Warning information to the customer WARNING Using a seat belt extender when not necessary is dangerous The seat belt will be too long and not tit properly In an accident the seat belt will not provide adequate protection and you customer could be seriously injured Only use th xtender when it is required to fasten the seat belt properly Using an extender that is too long is dangerous The seat belt SEAT BELT EXTENDERS DESCRIPTION ORDERING INFO CAT S NO 005 98 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 43PM will not fit properly In an accident the seat belt will not provide adequate protection and you could be seriously injured DO NOT use the seat belt extender or choose one shorter in length if the distance between th xt the user s body is less than 6 Using a seat belt extender that nder s buckle and the center of inches is for another person or a different vehicle or seat is dange
226. are being supplied with this bulletin Ensure COPY remains intact with the original bulletin so that additional copies can be produced as necessary by your dealership Your understanding and continued co operation are appreciated See Fig 1 for example AUTOMATIC TRANSMISSION DIAGNOSIS INFORMATION SHEET 1 Dealer Code RO Date Model Yr VIN Odometer 2 Customer Concern Check appropriate box Shifting Engagement Does Not Occur Slips Delayed Harsh A Engagement into drive B Engagement into reverse C 1 2 Upshift D 2 3 Upshift E 3 4 Upshift F Downshifts E G Kickdowns SEN E Noise Vibration Clunk Whine Buzz Other Condition Occurs Hot Cold Frequency Intermittent Always Other 3 Technician Diagnosis Visual Inspection note leaks REMANUFACTURED TRANS CANADIAN DIAGNOSIS SHEET CAT J NO 95 02 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 18AM Fluid Condition Burnt Normal Fluid Level Correct High Low Line Pressure record applicable data Idle WOT P N A R N N A OD D 2 1 Replacement Transmission Identification unit to be insta
227. battery 2 Raise the vehicle on a hoist or raise the front end with ramps 3 Disconnect the connectors at the starter 94453025 Fig 1 Disconnecting Starter Solenoid Connectors 4 Connect countermeasure harness FDY1 67 SHO as shown in Fig 2 A T NO START AFTER HEAT SOAK WIRE LENGTH INCREASED CAT G NO 001 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 19PM 94B53026 Fig 2 Installing Countermeasure Harness 5 Tape off OEM starter solenoid wire Secure countermeasure harness with 4 tie wraps E018 67C92 see Fig 3 Confirm there is no interference between the brake and fuel lines Borer 94C53027 Fig 3 Securing Starter Solenoid Wiring Harness PARTS INFORMATION TABLE 3 Part Number 3 Description 3 Qty ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 FDY1 67 SHO 3 Starter Wire Harness 1 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 E018 67 C92 3 Tie Wrap 3 4 3 AAAAAAKAAAAAAAABAAAAAAAAAAAAAAAABAAAAAABAAAAAAAAAAAAAAAAAAAAAAAAU WARRANTY INFORMATION Applies to Vehicles Covered Under Warranty Warranty Type Code A Customer Comment Code 02 A T NO START AFTER HEAT SO
228. com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM 3 Start the engine 1 Remove the circuit opening relay 5 After th ngine stalls crank the engine for 15 20 seconds to purge the injectors 6 Turn the ignition switch off 7 Install the circuit opening relay e ES Circuit Opening Relay 98H51646 Fig 2 Circuit Opening Relay 8 Disconnect the negative terminal from the battery NOTE Record all preset stations on the vehicle s audio system prior to disconnecting the battery terminal 9 Drain coolant and retain in an appropriate container 10 Remove the air intake pipe from the outlet of the turbo and cover the outlet with a shop towel RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Air Intake Pipe lt IE Cover Outlet With Shop Air Duct Towel 98151647 Fig 3 Air Intake Pipe intercooler 11 Remove the air duct from th 2 Remove hoses from the extension manifold See Fig 4 See Fig 4 13 Remove harnesses from the extension manifold RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM R
229. connector 3 switch off 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Is throttle sensor OK 3 Yes Check wiring and connectors 3 2 3 from EC AT control unit to 3 3 throttle sensor 2 3 3 If OK go to next step 3 3 If not OK repair wiring 3 3 3 EE 3No Adjust or replace throttle 2 3 sensor 2 Disconnect negative 3 Yes Replace EC AT control unit 7 battery cable for at least 3 20 seconds AA AAAAAAAAAAAAAAAAAAAAAAAAAAAA Connect battery cable and 3 Intermittent poor connection recheck for service cod 3 3 Check for cause 3 Is service code displayed 3 U EC AT ENGINE CONTROL UNIT CONTROL UNIT 94F 55446 THROTTLE SENSOR Service Code 12 Circuit Diagram WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair In
230. debris CALL MASH HOTLINE 3 3 3 2 3 accumulator is internal and not 3 3 serviceable CALL MASH HOTLINE 3 3 4 If cracked porous leakage damaged other 3 3 CALL MASH HOTLINE 3 AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM MASH AUTHORIZATION Before replacing a transmission assembly authorization must be obtained from the Major Assembly Service Hotline MASH This authorization is required for warranty reimbursement When it is necessary to contact MASH the information from the Automatic Transmission Diagnostic Sheet ATDS will be required by the hotline specialist before the situation can be reviewed The ATDS is used for documenting diagnostic finding for all transmission concerns AUTHORIZATION PROCESS 1 Dealer technician diagnoses the problem to determine if a complete assembly is required 2 Technician completes the ATDS 3 D NOTE aler Service Manager calls the MASH Hotline 800 832 4940 Service Manager selects 2 for the Major Assembly Service Hotline as prompted by phone voice mail Service Manager provides all information from the ADTS Service Manager provides an e
231. different from other cleaner burning gasoline used in the United States for several years If the vehicle is a California calibrated 1996 or later model the vehicle will Operate satisfactorily on gasoline in the other 49 states but the emission control system performance may be effected Using gasoline other then CaRFG may cause the Malfunction Indicator Light MIL to illuminate or cause the vehicle to fail an emission test CaRFG AFFECT ON FUEL ECONOMY A very small reduction in MPG less than one half MPG is possible if the customer uses gasoline without oxygenates This is attributed to the lower energy content of oxygenates which have been included in all Southern California gasoline since January 1995 and some gasoline since the 1970s NOTE Driving habits vehicle maintenance and weather conditions all affect fuel economy Fuel economy may vary more than 1 MPG from one fill up to the next using the same gasoline NO SPECIAL ADDITIVES ARE NECESSARY WHEN USING CaRFG It is not necessary to add anything to the vehicle s fuel tank after CaRFG is purchased from the service station California regulations require deposit control additives in CaRFG to avoid port fuel injector and valve deposits OLDER VEHICLE S PERFORMANCE USING CaRFG Older vehicles ar xpected to operate satisfactorily on CaRFG because these vehicles have been operating on gasoline sim
232. difficult to repair using existing Mazda repair manuals The followi ng list represents items most com n the blower unit an ed sealing gromm undiagnosed by the dealer 1 Air leakage betw 2 Missing or mis instal 3 Incorrect operation of the thermostat 4 ventilation system monly left unrepaired or d the cooler unit ets in the firewall Improper usage of the recirculation and fresh air mode of the In order to assist in the correct diagnosis and repair of Heating System concerns the foll See Fi g 1 for a visual owing troubleshooting manual was developed description of the Climate Control System HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM 94D50586 Fig 1 Climate Control System USING THIS MANUAL Follow the flow charts and diagnostic procedures below to repair the complaints which were determined on the Customer Comment Sheet 3 1 Complete customer 3 7 comment sheet i U 3 2 Determine Nature of complaint 3 3 a problem or b im
233. distributor and the secondary fuel distributor to th ngine S Fig 59 NOTE Replace the four insulators with new ones Insulator for primary N3A1 13 257 x 2 pcs Insulator for secondary NFO1 13 257A x 2 pcs 32 1 Apply adhesive to the hose end on the primary fuel distributor outlet side indicated by the arrow in Fig 59 To apply adhesive s step 27 1 13 257A N3A1 13 257 94B59338 f Fig 59 Installing Primary amp Secondary Fuel Distributors to Engine 32 2 Connect the hose between the fuel distributor and the vacuum RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 41 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM pipe assembly See Fig 60 NOTE Replace the clips outlet side of the secondary fuel distributor with new ones Clip Secondary 8574 13 157 For the direction of the clip claw see Fig 60 Do not use clips other than those included part number below Be sure to use two clips for the joint between the primary fuel distributor and the main fuel pipe see arrow in Fig 46 NOTE For the direction of the clips claw s step 27 2 Clip Primary N371 13 157 x 2 pcs Place the fuel distributor side clip claws on the
234. end Fig 20 Installation of Clips on Hose Install the protector Protector 94H59334 Fig 21 Installation of Protector 28 Install the fuel hose on the secondary fuel distributor See Piga 22 NOTE Place the connector stopper on the secondary fuel distributor body then tighten the connector bolts Tightening Torques 240 360 kgf cm 208 312 in lbf Use new gaskets Gasket N236 13 483 x 2pcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Reuse the connector bolts Gasket 94159335 Fig 22 Installation of Fuel Hose on Secondary Fuel Distributor 29 Replace the fuel hose on the return side of the secondary fuel distributor with a new one S Fig 23 NOTE Replace the clip also with a new one Do not use clips other than those included part number below Fuel hose N370 13 415 Clips o9574 3 157 Clip with Pink Colored holder For the direction of the clip claws see Fig 23 Do not place the clip on the pipe bulge 94159336 Fig 23 Return Side of Secondary Fuel Distributor Hose Replacement Place the Clip Claw on the Top Use New Parts RX 7 FUEL LEAKAGE RECAL
235. for at least 3 20 seconds AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Connect battery cable and No Intermittent poor connection recheck for service cod 3 Check for cause 2 Is service code displayed 3 3 U CIRCUIT DIAGRAM w w www w A 3 3 3 3 3 3 A EC AT CONTROL UNIT METER 15A SPEED SENSOR 2 94D55445 SPEEDOMETER SENSOR Fig 4 Service Code 07 Circuit Diagram M EE U 3 3 Service Code No 12 3 Throttle Sensor AAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Step Inspection 3 Action 5 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1 Are there any poor 3 Yes Repair or replace connector 1 3 connections at throttle 3 3 3 sensor and EC AT control AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 unit connector or terminal No Go to next step 2 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 2 3 Connect a circuit tester to Yes Go to Step 5 3 3 3 terminals 2T and ground as 3 i 3 3 sh
236. in Fig 13 E 3 3 Is output duty of solenoid 3 3 3 valve lockup at EC AT AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 control unit OK 3No Replace EC AT control unit 3 3 3 Acceptable Dwell 3 3 3 3 Approx 5 no lockup 3 i I 3 3 Approx 100 lockup z 3 5 3 Disconnect negative 3 Yes Replace EC AT control unit 3 3 battery cable for at least 3 3 3 20 seconds AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Connect battery cable and No Intermittent poor connection 3 recheck for service cod 3 Check for cause 3 3 Is service code displayed 3 AAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU EC AT CONTROL UNIT SOLENOID CONNECTOR SOLENOID VALVE LOCKUP 04155433 Fig 13 Service Code 63 Circuit Diagram p M eae ake ha ce D Service Code 64 Solenoid valve Line Pressure AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Step Inspection 3 Action 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
237. intake temperature sensor resistance A Remove air flow meter and allow to sit until its temperature is the same as the ambient temperature B Using a multi tester measure and record the resistance of the intake air temperature sensor terminals THAA E2 and the atmospheric temperature at that time See Fig 3 for terminal identification _ m Measure R sistance 94H53030 Fig 3 Air Flow Meter Terminal NOTE Use a multi tester with an accuracy equivalent of the FLUK 70 series CAUTION Refer to Fig 3 and the Standard Values table when measuring resistance STANDARD VALUES TABLE U AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Ambient Temp 3 Resistance Ambient Temp 3 Resistance 3 F 2 K Ohms 3 F 3 K Ohms 3 2 O 6 T87 70 2 24 9 3 A AARAAARAAARA AAA AAA RAA AR 2 10 3 E 80 co A 3 A A AR AAA RAA AA AAA RAA AR 3 20 3 6 4 10 3 3 90 3 2
238. new one Included in Kit vehicle has no coolant leakag xperienced and no coolant leakage at present proceed to PROCEDURE E PROCEDURE D REPLACEMENT OF THE WATER PUMP KIT NOTE Procedure D is continued from procedure E Water Pump Kit Part number N3Z1 15 320 Thermostat Gasket must be ordered separately and is not included in the Fuel Hose Parts Kit 38 Remove the bolts from the fresh air duct and remove the fresh air duct See Fig 66 Remove the rubber hoses from the air cleaner Remove the air cleaner installation bolts 39 Remove th upper radiator hose See Fig 66 LT 94E59349 Fig 66 Fresh Air Duct Bolts amp Upper Radiator Hose 10 Remove th alternator installation nuts from the alternator RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 47 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM adjuster bracket to remove the tension control bolt 41 Remove the water pump pulley and alternator belt See Fig 67 Loosen the four bolts from the water pump pulley Loosen the alternator belt Remove the bolts from the water pump pulley Move the belt and remove the water pump pulley remove tension control box 94159350 remove bolts remove water
239. of approved testing programs is available from EPA at the address on the back of this fact sheet SALES RESTRICTIONS The sale of any size containers of CFCs to anyone other than certified technicians is prohibited after November 14 1994 This provision is intended to discourage do it yourselfers who recharge their own air conditioners Such individuals often release refrigerant because they typically do not have access to recycling equipment The Agency encourages do it youreslfers to bring their cars to certified technicians who can properly fix air conditioners using approved equipment This avoids damage to A C equipment by improper charging and helps to protect the environment RECORD KEEPING REQUIREMENTS Service shops must certify to EPA that they own approved equipment If refrigerant is recovered and sent to a reclamation facility the name of that facility must be retained IMPACTS ON A C SERVICE Because of the planned CFC phase out and the tax on CFC s shops that service air conditioners can expect the price of CFC 12 to increase and its availability to decrease Widespread refrigerant recycling however reduces the need for virgin CFC 12 and thus helps keep costs down Refrigerant recycling is an important step towards the goal of eliminating CFC use It means that car owners can have their air conditioners fixed until alternatives to CFC 12 are develo
240. one sides Labor Operation PO113AMX 0 8 hrs 2WD Labor Operation P0113CMX 0 6 hrs 4WD Front Brakes Disc Plate s Machine on vehicl both sides Labor Operation P0113BMX 1 5 hrs 2WD Labor Operation P0113DMX 1 1 hrs 4WD Front Brakes Pad s R amp R one sides Labor Operation PO104ARX 0 4 hrs Front Brakes Pad s R amp R both sides Labor Operation PO1LO4BRX 0 7 hrs 93 B Series and earlier Front Brakes Disc Plate s R amp R one side Labor Operation PO1O2ARX 0 6 hrs 2WD Labor Operation PO102BRX 0 9 hrs 4WD VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 abor Operatio Labor Operatio abor Operatio abor Operatio abor Operatio Labor Operatio Front Brakes Pad Labor Operatio Front Brakes Pad Labor Operatio END OF ARTICLE Front Brakes Disc P Front Brakes Disc P Front Brakes Disc P D D oe oe oe 8 8 Article Text 11 For www iluvmyrx7 com 1993 Mazda RX7 Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM PO late s 02 R amp R CRX both side 3 1 nrs PO PO LO2 late s PO late s PO DRX 1 Machin 3AMX 0 8 3CMX 0 6 Machin MX 6 Mis nrs one sides on nrs nrs on nrs PO R amp R R amp R POI PO B
241. or A C component damage END OF ARTICLE YEAR 2000 COMPLIANCE CAT 01 NO 018 99 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 10AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN YEAR 2000 COMPLIANCE Model 5 All Mazda Models Category 01 Engine Bulletin No 018 99 Date May 28 1999 DESCRIPTION Because all Control Units including the Powertrain Control Modules used in Mazda vehicles do not use the day month or year to operate Mazda vehicles are completely immune to the effects of the year 2000 concern END OF ARTICLE HOLD INDICATOR LIGHT FLASHES REPLACE CONTROL UNIT CAT K NO 012 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 22AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN HOLD INDICATOR LIGHT FLASHES Model s 1993 Mazda RX 7 Category K Bulletin No 012 92 Date T4 15 92 DESCRIPTION On some 1993 RX 7 vehicles the torque reduction control fail diagnostic system may start working without any failure and cause the hold light to flash while the vehicle is running Beginning May 11 1992 the circuit logic of the torque reduction control has been changed to eliminate this possibility VIN OF PRODUCTION CHANGE JMIFD p0205980 May 11 1992 INSPECTION
242. part cannot be used in place of a new one END OF ARTICLE FUEL HOSE MAY LEAK FROM EXCESSIVE ENGINE HEAT Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 54AM ARTICLE BEGINNING NHTSA RECALL BULLETIN Model 5 1993 Mazda RX7 1994 Mazda RX7 Campaign No 95V069000 Number of Affected Vehicles 13400 Beginning Date of Manufacture 991 DEC Ending Date of Manufacture 1994 SEP VEHICLE DESCRIPTION Passenger vehicles SYSTEM Fuel fuel lines hoses non metallic FAULT Broken Shattered Cracked Split Collapsed DESCRIPTION OF DEFECT Residual engine heat can cause premature deterioration of the fuel hose causing the hose to leak Also removing and reinstalling the deteriorated fuel hoses increases the likelihood of a leak CONSEQUENCE OF DEFECT This condition can result in an engine compartment fire CORRECTIVE ACTION Dealers will install an additional control unit for the electric cooling fan The fan will then activate after th ngine is turned off when the coolant exceeds a specified temperature The fuel hoses will also be replaced with revised hoses NOTE If your vehicle is presented to an authorized dealer on an agreed upon service date and the remedy is not provided free of charge within a reasonable time please contact Mazd
243. pre delivery inspection operate the windshield wipers and washers at each speed interval low and high to ensure that the wiper blades operate without the above mentioned problems If there is a problem soak a clean cloth with an alcohol based solution and wipe the windshield and the windshield wiper blades to remove all dirt grime and any remaining transit coating Check the operation again and if there are any problems replace the wiper blades with new ones S Fig 2 NOTE Never use a corrosive or caustic solution such as Gasoline Thinner Benzene Alkaline detergent POOR WIPER BLADE PERFORMANCE CAT A NO 93 07 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 40PM ZZ Fig 2 Cleaning Wiper Blade 94H50234 END OF ARTICLE POWER ANTENNA MAST REPAIR PROCEDURE MT 0195 08 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 41PM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER POWER ANTENNA MAST REPAIR Model 5 All Mazda Models with Power Antennas Category Mazda Tips Bulletin No MT 0195 08 Date January 1995 DESCRIPTION You don t need to replace th ntire power antenna assembly if only the mast is defective Repair the mast using the following
244. procedure 1 Remove the mounting nut with snap ring pliers or a hook wrench See Fig 1 2 Have an assistant turn on the radio while holding the mast to avoid damaging the paint If the mast does not pop up use slip joint pliers to pull it up See Fig 1 NOTE If part of the plastic rack wire is broken inside of antenna motor the antenna assembly must be replaced 3 Clean the mounting hardware then spray a bit of lubricant on the nut 4 On the replacement mast carefully bend 3 4 inch of the plastic rack wire or feeder back about 3 8 inch for easy installation 5 Insert the rack wire into the assembly until it touches the pinion gear 6 Have an assistant turn off the radio At the same time guide the mast as it is retracted into the housing 7 Don t forget to tighten the mounting nut Mounting nut Useslip joint pliers to pull up mast ifnecessary 95D59603 Fig 1 Antenna Location POWER ANTENNA MAST REPAIR PROCEDURE MT 0195 08 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 41PM END OF ARTICLE POWER ANTENNA MAST REPLACEMENT CANADIAN CAT T NO 95 06 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 41PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN POWER ANTENNA MAST
245. pump pulley Loosen the alternator belt Remove the bolts from the water pump pulley Move the belt and remove the water pump pulley 94159350 remove bolts remove water pump pulley Fig 67 Alternator Bracket amp Water Pump Pulley 42 Remove the alternator adjuster bracket Remove the bolts attaching the alternator adjuster bracket to the water pump 43 Remove the nut attaching the alternator adjusting bracket to the power steering bracket See Fig 68 RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 48 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 9459351 Fig 68 Alternator Adjusting Bracket Nut to Power Steering Bracket Remove the water pump and discard Remove and discard gasket and clean gasket surface 45 Install new water pump using the new gasket See Fig 69 Water pump Included in Kit Gasket Included in Kit Install new water pump and gasket Clean surface prior to installation Fig 69 Installing New Water Pump Gasket NOTE Be sure that oil metering line retaining clip is installed RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 49 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM corr
246. pump pulley Fig 67 Alternator Bracket amp Water Pump Pulley 42 Remove the alternator adjuster bracket Remove the bolts attaching the alternator adjuster bracket to the water pump 43 Remove the nut attaching the alternator adjusting bracket to the power steering bracket See Fig 68 RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 48 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 94459391 Fig 68 Alternator Adjusting Bracket Nut to Power Steering Bracket 1 Remove the water pump and discard Remove and discard gasket and clean gasket surface 45 Install new water pump using the new gasket See Fig 69 Water pump Included in Kit Gasket Included in Kit Install new water pump and gasket Clean surface prior to installation Fig 69 Installing New Water Pump Gasket NOTE Be sure that oil metering line retaining clip is installed RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 49 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM correctly on the outside of the water pump at bolt A See Fig 70 94B59353 Fig 70 Oil Metering Line Retaining Clip Identification 46 Disconnect the low
247. rough roads do not replace the door mirror Twist the mirror downward to expose the two 2 mounting screws that attach the mirror to the body See Fig 1 Remove the mounting screws and apply loctite blue type to the threads and reinstall the screws very firmly to ensure the vibration has been eliminated N Q Ju d I E p om Fig 1 Location of Mounting Screws END OF ARTICLE DOOR TRIM RECESS BROKEN RECESS AVAILABLE SEPARATELY MT 0395 03 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 36AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN DOOR TRIM RECESS BREAKAGE Model s All Mazda Models equipped Category Mazda Tips Bulletin No MT 0395 03 Date March 1995 DESCRIPTION If the door trim recess is broken do not replace th ntire door trim The recess is available separately as a service part for all models The complete door trim is not warrantable if it was replaced to repair a broken recess See Fig 1 4 Door Trim Recess 94058012 Fig 1 Door Trim Recess END OF ARTICLE ENVIRONMENTAL FALLOUT REPAIR PROCEDURE MT 0797 07 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 36AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER ENVIRONMENT
248. test leads TEST LEAD AUX SIG RED GREEN 98E54134 Fig 1 NGS Tester INSPECTION PROCEDURE 1 Verify concern INSPECTION PROCEDURE FOR TEST LEAD OF NGS TESTER CAT ST NO 006 98 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 08AM 2 Select Ohm Meter on the tester and connect a test lead between the COM black and SIG red terminal on the NGS tester and note the reading A reading of O ohms indicates that the test lead and connections do not hav xcess resistance A reading other than O ohms may indicate a poor connection go to STEP 3 3 Disassemble the connectors and check for corrosion solder breakage or looseness Resolder connections to repair as necessary See Fig 2 4 Verify repair DISASSEMBLED VIEW OF CBS ASSEMBLED VIEW OF SCREW TYPE CONNECTOR SOLDER HERE DISCARD SCREW AR 98F54135 Fig 2 Assembeled Disassembled Connectors END OF ARTICLE R 12 CFC WARNING LABEL INFORMATION CAT U NO 002 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 08AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN R 12 CFC WARNING LABEL Model 5 All models produced after May 15 1993 that do not have R 134A air conditioning units Category U Air Conditioni
249. the unit must be returned properly Failure to return a complete core and the required information will result in no core charge refund To receive core credit you must Return the transmission within 30 days of the vehicle repair date Return it in the special shipping container Completely drain the transmission fluid Assemble all components and install hole plugs differential side gear and torque convertor holding devices Complete and attach the core return tag Complete and attach a copy of the Automatic Transmission Diagnostic Sheet IMPORTANT NOTE The 600 core charge will not be refunded if the dealer fails to perform these tasks or if the transmission is damaged during shipping due to improper preparation CORE COMPONENT DETAILS Install the torque convertor by rotating it to align the splines of the bearing cover turbine shaft and oil pump Ensure the torque convertor is fully installed to prevent bushing damage during shipping See Fig 1 Fully Install Torque Convertor 24150908 To Prevent Bushing Damage Fig 1 Installing Torque Converter Install torque convertor retaining bracket See Fig 2 AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 16 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM x Ins
250. top and the other one on the bottom N3Z1 13 157 x 2 94059339 Turn the clip claw sideways Dashboard side A B 8574 13 157 Fig 60 Connecting Hose Fuel Distributor amp Vacuum Pipe Assembly Place the Clip Claws in Opposite Directions RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 42 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 32 3 Replace the main fuel hose with a new one S Fig 61 NOTE The hose and the clips shown in Fig 61 should be replaced with new ones Be careful not to use the hose and the clips other than those included part number s below Apply adhesive to the hose end short end side only indicated by the arrow in Fig 61 then install it To apply adhesive s step 27 1 Insertion depth of both hose ends should be 25 30 mm Fuel hose N3Z1 13 421 Clip 8574 13 157 x 2 pcs Short end 94F59340 Fig 61 Replacement of Main Fuel Hose 33 Check for fuel leakage WARNING Do not smoke carry lighted tobacco or an open flame of any type when working on or near a fuel related component Highly flammable mixtures are present and may be ignited resulting in possible injury 1 Connect the negative terminal to the bakery 2 Connect the fuel pump terminal of the diagnostic connector to RX 7
251. vehicle s front May 31 992 install a repair windshield molding Lift the w foam into the space between th Fig Fig indshield molding and slide the sealing 94B53984 Seal Foam Kit Install molding and the windshield See ation Vehicles produced afte front windshield molding The r May 31 PARTS INFORMATION TABLE mber 3 Description 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 739 3 Repair Seal Foam Kit 3 Part Nu 3 B001 77 1992 are equipped with a modified sealing foam is attached to the molding WHISTLING NOISE FROM THE WINDSHIELD MOLDING CAT S NO 049 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 44AM U WARRANTY INFORMATION Applies to Vehicles Covered Under Warranty Warranty Type Code A Customer Comment Code 81 Damage Code 99 Part No of Main Cause B001 77 739 Operation No 0422XRX Labor Hour 0 2 Hrs END OF ARTICLE WIND NOISE AROUND DOORS CAT S NO 018 98 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 200
252. warned of a low water level prior to the point where enough coolant had been leaked to present any serious risk of fire Detailed information regarding this Recall Campaign is provided in CONDITION OF CONCERN section with additional information concerns in VEHICLES WITH A HISTORY OF A COOLANT LEAK the letter sent to the owners of the subject vehicles is in OWNER NOTIFICATION LETTER section and the repair procedure is given in SERVICE PROCEDURES section In an effort to demonstrate concern for customer satisfaction we are requesting you to do the following two items Upon completion of the repairs as part of a dealer effort to demonstrate concern for customer satisfaction wash the vehicle vacuum the interior and clean the windows before returning the RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM vehicle to the customer Call the customer within 48 hours of the recall repair s completion to ensure that the vehicle is performing satisfactorily If there are any unresolved concerns the customer brings to your attention schedule an inspection date to address the concerns The National Traffic and Motor Vehicle Safety Act prohibits selling or leasing any subject vehicles without performing the necessary repair for defect
253. with the wheel This is caused by the contact between the cap and the axle flange See Fig 1 Aluminum Wheel Center Cap I Center Ca Pr spl P Contact Area shaded I Axle Flange I E Axle Flange 93B56375 Fig 1 Center Cap Axle Flange Contact REPAIR PROCEDURE If this condition occurs the center cap s should be replaced with a modified one PARTS INFORMATION TABLE Part Number Description Int Quantity New Old WHEEL CENTER CAP STICKS OUT MODIFIED CENTER CAPS CAT Q NO 003 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 26AM 37 1918 37 191A Cap Center A 4 NOTE Interchangeability code A means that a new part can be used in place of an old one but an old
254. yasa 3 EE E PCM TCM Powertrain Control Module Transmission Control Module 3 3 OCTOBER 1995 SPECIAL TOOLS SHIPMENT CAT ST NO 007 95 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 40PM 3 3 CCM Cruise Control Module 3 3 4 On vehicle control unit equipped with OBD II 3 5 Includes Traction Control System E 3 0 Means there is no TCM but it is possible to diagnose 3 the TCM from the PCM menu 3 X Means these year models are newly added to the program 7 3 card z U END OF ARTICLE PARTS REPLACEMENT AFTER AIRBAG DEPLOYMENT CAT T NO 007 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 40PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PARTS REPLACEMENT AFTER AIRBAG DEPLOYMENT Model s 1993 97 Mazda 626 MX 6 1992 95 Mazda 929 1995 97 Mazda Millenia 1993 97 Mazda MPV 1994 95 Mazda MX 3 1990 97 Mazda MX 5 Miata 1995 97 Mazda Protege 1988 91 Mazda RX 7
255. your dealer 2 This program has been developed with a tracking system that will ensure the original harness adapter that your dealer submitted is the same one returned back to you 3 Since Mazda cannot update all 900 dealer harness adapters at once the program will be implemented one region at a time This will help alleviate potential confusion and delays The following table lists each regional office and the date their dealers will be sent a Fed Ex box for them to begin participating in the program Be sure to note when your dealer will be shipper its Fed Ex box DATE IMPLEMENTATION TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAR Mazda Office 3 Implementation Date 3 3 Mazda Great Lakes 3 7 11 94 3 3 Gulf 7 18 94 3 KAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Northeast 3 7 5 94 3 AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Northwest 3 7 25 94 3 3 Pacific 3 6 27 94 2 AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Southeast 7 25 94 I
256. 0 533 0492 3 3 3 Part Number Description 3 J 3594 AMAZ 3 Flushing Kit 60081 3 Portable Torque 3 3 Converter Oil 3 3 Cooler Cleaner 3 U The Kent Moore flushing equipment will be available soon A Special Tools Bulletin will NOTE Ts 2 be released which will contain further details Power flushers require a 5 Micron filter installed The above flushers requir vehicle applications adapters attachments for Mazda Direct all questions regarding usage and application to the flusher manufacturer Flush in reverse direction o f normal operation Refer to the workshop manual for normal flow Refer to Fig 4 AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 18 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM Flushing Procedure 1 Backflush Cooler Start ing At The Cooler OUT Line
257. 0 91 929 1989 92 MPV 1989 91 RX 7 7 Short circuit the fuel pump check terminal and the ground terminal of the diagnostic connector with a jumper wire on the following vehicles s Fig 7 1990 93 323 Protege 1993 626 MX 6 1992 93 929 1992 93 MX 3 1990 93 MX 5 1993 RX 7 ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM 94B53034 Fig 7 Short Circuiting Fuel Pump 8 Turn the ignition switch on and measure the maximum fuel pressur Turn the ignition switch off and remove the jumper wires See FUEL PRESSURE TABLE For standard values FUEL PRESSURE TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Year Model 3 Standard Value PSI 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAAAA 3 1988 89 323 3 49 or Over 3 3 1990 91 323 Protege 3 3 3 1990 92 626 MX 6 3 E 3 1990 91 929 3 3 3 MPV All 3 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAAAA 3 1992 93 323 Protege 3 52 or Over 3 3 1992 93 929 3 3 3 1993 626 MX 6 3 3 3 MX 3 All 3 3 3 MX 5 All 3 3 3 1989 91 RX 7 3 56 or Over 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 1993 RX 7 3 53 or Over 3
258. 00 new coolant COOLANT TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Concentration of Amount of Anti Freeze BAnti Freeze To Be Added 3 oA 55 3 4 4L 3 AAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAABA 3 5 10 3 4 1L 3 3 0 Hire 3 3 8L 3 15 20 5 3 5L RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 24 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM j 20 25 5 35 TE 7 25 30 5 H 2 7L 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 3 30 35 7 2 2L 35 40 5 N 6L 3
259. 0667R1 XX0667R2 3 XX0667R3 3 Operation 3 3 3 3 Code 3 3 3 3 ARAAAAAARAAAAAARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Labor 3 0 3 Hrs 2 2 Hrs 3 8 3 Hes 2 3 Hours 3 3 3 3 U OWNER NOTIFICATION LETTER The owners of the subject vehicles will be notified by first class mail beginning August 8 1994 Please s attached letter 1993 94 RX 7 Coolant Leak Recall Campaign 54407 Dear RX 7 Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Mazda has determined that a defect which relates to motor vehicle safety exists in certain 1993 94 RX 7 models We have decided to conduct Recall Campaign 54407 for replacement of selected engin cooling system components in those vehicles beginning August 8 1994 If your RX 7 has been subjected to high speed operation and then parked before cooling down the residual engine heat combined with the build up of pressure in the cooling system can raise the temperatur of the coolant to levels wher
260. 07 Article Text p 27 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM the n marke umber of subject vehicl t area s registered in the dealer s assigned Parts ordering will be open to dealers beginning August 29 1994 NECESSARY PARTS TABLE 3 Part Description 3 Part Number 3 Qty 3 3 Campaign Door Label 3 P N 9999 95 065A OO Qty 1 3 AAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAARAAAARARAARAAAAA 3 Owner s Manual Label 3 P N 9999 95 073A 94 3 Qty 1 3 AAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAARAAAAR Under hood Coolant Mix Label P N 9999 95 074A 94 3 Qty 1 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Filler Cap Kit 3 P N N3Z1 15 S1 OB 7 Qty 1 3 AREA ARRAN AAA AR AR AA AR ARR ARR RARE AREA Pn nn y n RANA LARA 3 Throttle Water Hose Kit i P N N3A1 13 S60 Qty 1 3 3 Ther
261. 0E AND REPROGRAMMING OF V2 02 49T0 88 010E Model 5 1988 98 Mazda Models Category ST Special Tool Bulletin No 004 97 Date October 10 1997 DESCRIPTION Per Special Tool Service Bulletin 006 96 issued November 21 1996 your dealer should currently have two reprogrammable New Generation Star NGS cards One card contains an older Version 2 02 P N 49T0 88 010C and the other card contains your most current Version 3 0 P N 49 TO 88 010D Your most current Version 3 0 has been superseded to Version 4 0 P N 49T0 88 010E It includes new 1998 service information This new version is a Mazda Required Tool MRT since it is used with the NGS tester to properly service MAZDA vehicles Mazda s tool vendor America Kowa Seiki Inc AKS is offering a reprogramming service which will update your older Version 2 02 to Version 4 0 at a substantial savings Follow the REPROGRAMMING PROCEDURE to participate in this service NOTE If your dealer chooses NOT to participate or cannot participate in this reprogramming service a new card with V4 0 will automatically be shipped to your dealer at a substantially higher price APPLICATION This card is used with your NGS tester to properly service 1988 98 Mazda Vehicles Refer to your Workshop Manual for the application of this card and the tester PRICING The price for the V4 0 reprogramming service is 210 00 plus return shipping cost
262. 0N310S 92 18 JANYA 010 3105 62 18 JANYA 010N3108 b2 18 JAVA 3 05 C2 18 u0SN3S0HB3H 1304 22 19 LE SD 843 VOSN3S 3 HILIAS 5 4 12 18 Gate qs pats v jun 3 JD lt U kv X MEO ie 32 32 52 18 ox LI XE eect HR YOVNY277 6 1 10 2377 1 un 33 10 14 21 8 NO1123S D t 053 tye 9 NOIL23S 4 3 NOLLD3S 40 2 NOTLD3S 2 8 NOI1235 z N01123 HOLTAS 834070 HOLIAS 8319013 NYA HOLTAS 4 H N011339 418 2 8 N0112351 UON Md LINN 1OMINOO HilY3M NOIIYNIBMOO IN3WDHISNI OWHJHL 831 LINN ae ion 3 8 88 51 2 N011228 ZO qj 2 Co 62 7 T 1 18 H31S042 8138 NYS 9 fon D be d sn ann 4 2 1738 OWUSHL AD 8 0 A HOLIAS ANIHAULSNT 5 2 3 4 y 61 18 NO1133S d f NO113359 M 22 18 HDD ENSE SISON9YIO 831170 kaf W3 1 88 12 18 1 243 3 ex GT aun Val VA 8 5 Vi i vA 243 4 u8 Ea Yo 2 N011236 4 ED 4 EX nan ey a 11 23 Waras 0 8 A 8 A 1 4 1 0 01 asa ul 410 Y Lex 28314 91 8 U 8 UOLIGIHNI gt Un ut py L N011235 L t 335 en n A1 83 VA L0 X 10 AYT3 NIYW 0 H21146 YA 310 Wak a9 193 4 8 4207831 1 u31uviS Wa WH TEL 3 ua 31 3 131 wa W3 ME A wn Ua 0 3 1 079 u 8 x M 8 21 897 8 l gt 151 52 18 82 18 92 18 se 18 v2 16 8 I eu SS xe SSv418 SvdL 8931 21188 t 3
263. 1 216 328 1500 Approval Date 8 12 92 International Mobile Air Conditioning Association P O Box 9000 Fort Worth TX 76147 2000 817 338 1100 Approval Date 6 29 92 Mechanic s Education Association 10 Main Street Netcong New Jersey 07857 1111 201 426 9001 Approval Date 3 30 93 HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Mobile Air Conditioning Society P O Box 97 East Greenville PA 18041 215 679 2220 Approval Date 6 12 92
264. 1 158 00002 014 00900 3 3 Sun amp SPX 3 023 00100 0078 00802 078 00800 3 078 00801 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 RISE 3 Port O Zone Automotive 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Saturn SPX Robinair 3 42 A7250 17400ASAT 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Snap On Tools 3 ACT2500 ACT3000 ACT3300 3 Company 3 ACTR3000 ACTH3400 AAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA SPX Corporation 3 12134A 12135A 17251C 014 00900 AC17145 GM17250B J38100B C 17400A 17401A 17500B 17501B 7503B 17300 01 03 50 51 51C 52 52C 53 3 Robinair Division 3 3 3 3 53C 5407 5556 3 3 3 3 3 3 17400 01 03 25 117666 177100 0l 03 2 5z 17800 17150 17151A for use with models 17350C 17351C 17500 3 17500B 7501B and 17625A only w w www iw 3 3 3 3 3 3 3 3 3 3 3 3 Sun Electric 3 MRC 150 300 312 400 500 3 3 Corporation 3 MTC 4000 NAPA 1100 5000 A9950 3 2 ATC 1000 1100 5000 078 2 3 3 00800 00801 00802
265. 1 07 44AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WIND NOISE AROUND DOORS Model s All Mazda models except MX 5 Miata and MX 6 Category S 09 Body Bulletin No 018 98 Date July 29 1998 DESCRIPTION Wind noise around doors may occur with some vehicles This may be caused by the door weather strip seal Customers complaining of this should have their vehicl inspected and repaired according to this service bulletin REPAIR PROCEDURE 1 Verify customer complaint 2 Examine weather strip for the following conditions a Rips tears cuts b Loose or falling off c Excessive deterioration If the weather strip has any of the above conditions replace it Go to step 3 If weather strip does not have any of the above conditions but wind noise still exists proceed to the CARD TEST CARD TEST 1 Open the door and insert a business card 0 2 mm thickness between the door and the weather strip at the base of the A pillar Close the door See Fig 1 2 Slide the business card up along the A pillar See Fig 1 a If the card slides easily at any location along the A pillar the sealing contact between the door is insufficient and requires adjustment Proceed to DOOR ADJUSTMENT b If there is consistent resistance proceed to the WHITE GREASE TEST WIND NOISE AROUND DOORS CAT S NO 018 98 Article Text p 2 1993 Mazda RX7 For www
266. 102ARX 0 4 hrs Front Brakes Disc Plate s R amp R both side Labor Operation PO208CRX 0 7 hrs Front Brakes Disc Plate s Machine on vehicl one sides Labor Operation P0113AMX 0 7 hrs Front Brakes Disc Plate s Machine on vehicl both sides Labor Operation PO113BMX 1 2 hrs Front Brakes Pad s R amp R one sides Labor Operation PO104ARX 0 4 hrs Front Brakes Pad s R amp R both sides Labor Operation PO1LO4BRX 0 6 hrs Navajo Front Brakes Disc Plate s R amp R one side Labor Operation PO1O2ARX 0 6 hrs 2WD Labor Operation PO102CRX 0 8 hrs 4WD Front Brakes Disc Plate s R amp R both side Labor Operation PO102BRX 0 9 hrs 2WD Labor Operation PO102DRX 1 2 hrs 4WD Front Brakes Disc Plate s Machine on vehicl one sides Labor Operation PO113AMX 0 8 hrs 2WD Labor Operation P0113CMX 0 6 hrs 4WD Front Brakes Disc Plate s Machine on vehicl both sides Labor Operation P0113BMX 1 5 hrs 2WD Labor Operation PO113DMX 1 1 hrs 4WD Front Brakes Pad s R amp R one sides Labor Operation PO104ARX 0 4 hrs Front Brakes Pad s R amp R both sides Labor Operation PO1LO4BRX 0 7 hrs 94 B Series and later Front Brakes Disc Plate s R amp R one side Labor Operation P0O102ARX 0 5 hrs 2WD Labor Operation PO102CRX 0 7 hrs 4WD Front Brakes Disc Plate s R amp R both side Labor Operation PO102BRX 0 8 hrs 2WD Labor Operation PO102DRX 1 1 hrs 4WD Front Brakes Disc Plate s Machine on vehicl
267. 110 kgs cm 70 95 in lbs 98 151622 Fig 7 Cooling Fan Control Module INSPECTION 1993 RX 7 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 With the cool Artic le Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM an control 1 the voltage at each terminal of tive ground the nega ing Po the c lead to the each terminal oi 2 I are correct systems are normal there is any incorrect inspect related systems the connector replace the cooli onnector module connector connected measur Using a voltmeter See Figs 8 thru 10 fan control module ng 98A51623 Fig 8 Fan Control Module Connector Terminal Locations Terminal Voltage Engine cooi Engine coot ant tempera ant tempera ture for cook ing fan ture switch Engme coolant temperature below 108 C 226 F Engine coolant temperature above 108 C 226 F 98F51743 Fig 9 Termin Cooling fan relay No 2 4 Cooling fan relay No 2 4 NEN J Ground Ground al Voltage Chart A J Cooling fan not operating During cooling fan operating Below 1 0 body and insert the positive lead in output voltage while all input voltages When the B Battery positive v
268. 1990 and must have the capacity to purify used refrigerant to SAE Standard J 1991 for safe and direct return to the air conditioner following repair Recover only equipment removes the refrigerant from the A C unit as specified by SAE Standard J 2209 and transfers it into a holding tank HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Technicians are then required by law either to recycle the used refrigerant on site or send it to an off site reclamation facility to be purified to ARI Standard 700 before it can be used to recharge A C equipment A list of approved equipment is available from EPA at the address on the back of this fact sheet Most certified equipment will be labeled AC design certified to SAE standards TECHNICIAN TRAINING AND CERTIFICATION Technicians who repair or service motor vehicle air conditioners must be trained and certified by en EPA Approved organization Training programs must cover use of recycling equipment in compliance with SAE Standard J 1989 the regulatory requirement the importance of refrigerant containment and the effects of ozone depletion To be certified technicians must pass a test demonstrating their knowledge in these areas A list
269. 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 41PM base of the antenna motor NOTE For replacement parts refer to the applicable parts microfiche 8 Assemble rubber bushing and mounting nut Tighten nut 9 Verify operation Antenna Mast pA Mounting Nut Rubber Bushing Fa 94J57405 Fig 1 Exploded View of Power Antenna Mast Plastic Rack 6 Teeth or 3 4 3 8 Insert Plastic Rack Into Assembly Until Contact is Made 94457406 j Fig 2 Plastic Rack Insertion Into Power Antenna Assembly END OF ARTICLE RADIO REMOVAL TIPS W CD PLAYER CAT T NO 018 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 42PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RADIO REMOVAL TIPS W CD PLAYER Model s 1993 Mazda RX 7 Category T Bulletin No 018 92 Date 9 92 DESCRIPTION Some 1993 RX 7 radios have been returned for service with damaged antenna leads This is caused by improper radio removal The removal procedures below should be followed to avoid damage to the antenna leads NOTE After installing the replacement radio advise vehicle owner to input the radio s anti theft code If needed refer to the owner s manual for details REMOVAL PROCEDURE 1 Re
270. 2 96 Up dated reference pages for the applicable Wiring Diagrams NOTE Many driveability concerns occur from improperly performed repair procedures This information is provided to emphasize this point and give direction to prevent these concerns REPAIR PROCEDURE IMPORTANT Read this information thoroughly prior to performing recall repairs MAZDA TIPS Jan 1994 ed When performing the Fuel Line Recall on RX 7 Recall 60504 the following precautions and tips could save you a lot of extra time and eliminate unnecessary expenses Use extreme caution when removing the Fuel Pressure Regulator vacuum line The plastic solenoid pipe can be easily broken when removing the hose if caution is not exercised Secondary Fuel Rail Hose Replacement The fuel injector rails are very fragile and can be easily broken Remove the fuel distributor assemblies before you remove the Fuel Connector bolt Do not mount the fuel distributor in a vice Hold the distributor in your hand SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM and remove the Fuel Connector bolt with an air impact wrench When installing the new fuel hose hold the fuel distributor by hand and torque The fuel connect
271. 2 gt 1 9 3 AARAAARAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAAARA 3 30 4 9 1 9 3 LOO 01 9 co 1 5 AARAAARAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAARA 3 40 3 6 0 L10 3 0 28 1 3 3 AARAAARAAAARAAARAAARAAAAAAAARAAARAAARAAAAAAAARAAARAAARAAAARAAARAAARA 3 50 3 0 4 7 L20 2 0 67 Lo 2 AARAARAARAAARAARAAAAAARAARAAAAAARAAAAAARAARAARAAARAAAAARAAARAAAAAAAA 60 3 ud ceu 3 2 ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM U 2 Check resistance between E2 and Vc See Fig 4 Standard Value 200 400 ohms wer Do Not Loosen These Screws NOTE If the screws are loosened or re moved the warranty claim will be rejected 9415303 1 Fig 4 Air Flow Meter Resistance Check NOTE Use a multi tester with the accuracy equivalent of a FLUK 70 Series The following models have air flow meters with measuring plates and should be diagnosed using the method listed below 1986 89 323 1990 93 323 Protege 1990 92 626 MX 6 1990 91 929 1988 93 MPV 1990 93 MX 5 1993 MX 3 1 6 Li
272. 3 Keep Check Sheets At Dealer 3 Attach to R O 3 3 Warranty Claim 3 Application 3 SECTION 3 FUEL PUMP DIAGNOSTIC PROCEDURES 1 Disconnect negative terminal and check battery voltage Voltage should be 12 4V or more Reconnect terminal 2 Start engine and run at idle ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM 3 Disconnect circuit opening relay Engine will continue to run until all fuel in the supply line is used WARNING Step 3 is designed to eliminate fuel in the supply line and nable safe installation of the fuel pressure gauge Refer to the appropriate service information for further instructions 4 Disconnect the negative battery terminal 5 Install the fuel pressure gauge on the outlet side of the fuel filter See Fig 6 for illustration 94453033 Fig 6 Checking Fuel Pressur 6 Short circuit the fuel pump test terminals yellow 2 pin connector with a jumper wire on the following vehicles s Fig 7 1988 89 323 1993 626 MX 6 199
273. 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM S RY P RY C Fuel Pe Hose 1 Hose 06009 EL 5 BY O M 9 OR 3 2 N Fuel pipe D p main ANN See step 32 2 Q 2 i Water hose Oa We 8 NS Q Orange White CA 2 i C79 mp Out 9 fw n 94459328 Fig 15 Exploded View of Tubes amp Hoses for Modification 24 Removal of primary fuel distributor secondary fuel distributor and insulator See Fig 16 1 Loosen the four bolts 2 Loosen the connector bolt from the inlet of the secondary fuel distributor Bolt Fuel Connector 94A59329 Fig 16 Removal of Primary amp Secondary Fuel Distributor amp Insulator RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM 25 Remove the fuel hose from the primary fuel distributor See Fig 17 NOTE When turning the screw be careful not to break the heads of the screws F two because they are tight Be careful not to damage the pipe at the hose insertion location on the primary inlet side 94D59330 Fig 17 Removal of Hose from Primary Fuel Distributor 26 Install the modified fuel hose
274. 3 3 connected See Fig 2 3 RAARARAAAARARAARARAAAARARAARARAARARARARARARARARAARARARRARARAAAA Turbo Control Improper Refer to Fig 2 to Valve Actuator Operation identify components for Charge Control Improper damaged bent nicked or removed condition Carefully check the ollowing 3 3 3 Valve Actuator 3 3 3 Improperly connected 3 3 3 3 3 3 Charge Relief Valve Turbo A 3 3 3 3 3 3 3 Piping Bent 3 3 3 3 3 Control Actuator 3 3 3 3 3 3 3 3 3 3 3 3 A Nicked and Removed Hoses Turbo Pre Control Actuator in Fig 2 piping around area Less Removed hoses around area H MI hose for bent condition U w w QU w Repair or replace defective parts as necessary Fig SYSTEM SCHEMATIC PARTS IDENTIFICATION TABLE 2 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM SYSTEM SCHEMATIC B Negative Press Check Vaive Solenoid Valve Turbo Pre Control Solenoid Vaive Turbo Control Pressure 1 Chamber Solenoid Valve Wastegate Con
275. 3 2 80D26L 3 35 3 30 3 195 MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1994 97 B 3 BX 58C 2 35 3 20 E 270 3 Series 3 BXT 65 650 3 35 3 20 s 325 2 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Navajo 3 BXT 65 650 3 35 I 20 7 325 5 U BATTERY DIAGNOSTIC PROCEDURES VAT 40 LOAD TESTER OR EQUIVALENT 1 Start engine and confirm that alternator warning light is not illuminated NOTE If the warning light is illuminated the self diagnostic function is operating Check the alternator and related harness Refer to the instructions in section G of the applicable workshop manual 2 Check the alternator belt tension and condition 3 Turn the vehicle headlights ON Check engine belt and alternator bearing for unusual noise by raising and lowering the engine RPM 4 Turn ignition and all accessories OFF 5 Connect the load tester 6 Apply the load test referring to the FACTORY INSTALLED BATTERIES INFORMATION TABL
276. 3 3 3 3 Approx 1 8 volts 3 3 3 3 3 ATF temp 10gC 508F 3 3 3 Approx 1 1 volts 3 3 3 3 ATF temp 40gC 104gF 3 3 3 3 Approx 0 4 volts 3 3 3 3 3 ATF temp 809C 1769F 3 3 3 WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM Disconnect 20 pin EC AT control unit connector Is resistance between 2R terminal and 2L terminal OK Acceptable Resistance Approx 3 8 Kohms ATF temp 109C Approx 1 2 Kohms ATF temp 40 Approx 0 3 Kohms ATF temp 80 508 F Hj 1049F QE w 1769F 4 Disconnect solenoid connector Is resistance between G terminal and H terminal of ATF thermosensor OK Acceptable Resistance Approx 3 8 Kohms ATF temp 109C Approx 1 2 Kohms ATF temp 40 Approx 0 3 Kohms ATF temp 8006 508 F 1046 F A 3 3 3 3 3 3 3 3 3 3 3 3 w w www iw 17656 F 5s Disconnect negative battery cable for at least 20 seconds Connect battery cable and recheck for service cod Is service code displayed w w pr ww gt EC AT CONTROL UNIT ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Yes Go to Step 5 3 3 3 3 3 3 3
277. 3 Gasket P N Remarks 3 1992 93 MX 3 1 6L I 4 B66S 02 300 3 8AE2 02 310 3 31994 MX 3 1 6L 1 4 B6DC 02 300 3 8ABD 02 310 3 3 1992 94 MX 3 1 8L V 6 K8Y1 02 300 3 8AE3 02 310 3 MILLENIA NEW ENGINE AVAILABILITY PARTS TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Year Model 3 Engine P N Gasket P N Remarks AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 31994 MILLENIA 3 KJY2 02 300 7 8AK1 02 310A 3 3 2 3L V 6 MILLER 3 3 3 3 PARTIAL ENGINE
278. 3 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 10AM b Small amounts of the tracer dye will be found in the Recovery Recycling tank if recovery is necessary TRACER DYE SUPPLIERS TRACER DYE SUPPLIERS INFORMATION TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Supplier 3 Available At 7 Part Number Note 3 3 Spectronics 800 641 1133 3 SS sm 3 Or Equivalent 3 3 Corporation 3 3 Equivalent 3 5 3 2 3 Ford 3 See Dealer 7 112 R0027 Or Equivalent 3 Rotunda 3 3 U REFRIGERANT COMPRESSOR OIL REFRIGERANT COMPRESSOR OIL INFORMATION TABLE AAAAARARAAAARAAARAAAARARAARARAAAAAAAARAAAARARAARARAAAAAAAAAAAAAAA P 7 3 Compressor 3 3 Model 3 Model Year 3 Refrigerant Oil Type
279. 3 connections at engine 3 3 3 control unit and EC AT A AAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 control unit connectors 3 No 3 Go to next step 3 SCA Connect a circuit tester 3 Yes Go to Step 5 to terminals 2C and ground 3 3 as shown in Fig 9 3 E 3 Is input voltage of 3 3 3 atmospheric pressure sensorAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAA w w www w 3 3 3 3 3 at EC AT control unit OK Go to next step 3 3 Acceptable Voltages 3 3 3 3 2 0 4 5 volts ignition 3 3 3 switch ON 3 3 3 3 0 volts ignition switch 3 3 3 3 OFF 3 3 3 AAKAAAAAAAAAARAAAARAAAABAAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAAAAAAAAAAAAR 3 3 3 Disconnect 20 pin EC AT 3 Yes Go to next step 3 3 control unit connector 7 3 3 3 Is there continuity 3 3 3 3 between 2C terminal of AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA EC AT control unit and 2D No Repair Wiring 5 WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM 3 terminal of engine control 7 3 3 unit 3 3 3 AAAA
280. 31738 984 aly 2 331138 aly s u 5 4 4 8 4 4 JAVA 340A JAVA JAWA 140 3 11745 30123CK1 801230 NI u0133CNI 801230 QI0N3108 010N3105 010N310 010N310S BATYA 0168310S BATA 010N310S Q10N310s ist i t im 62 18 92 18 L2 18 92 18 2 18 ZA t2 18 onn eese 2 on 31 wa ad 31 3 12 o 43 d ES 178 Me 8 8 8 Ave A a cor a 112351 448 ae Ma 51 8 NOI133S TEL un twa 643 twa 13 argu uva am t3 03 38 A 8 ara A 8 A a Ve D 193 1 8 4 8 178 3 193 W3lSAS 1OMINOO 3nd WALSAS 1081NOO ANIONS 8 WVHOVIC ONIHIM 7 98051625 amp Fuel Control System 1993 RX 7 ine iring Diagram Eng W E TRS sry k s Oo 5 On DD z wrs lt i o LL Copyright 1998 Mitchell Repair Information Company LLC SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 39AM Saturday August 25 2001 09 1 8 664 2x31 ON NOISSIW3 t J11N0Hj N334138 YOLDINNOD t1 28 4 24312 0N NOISSIN3 Y 3 1NO S N334138 N0123NND2J 01 28 4 khouo t2w3 2 QN HOISSIN3 3 1N0H3 N33A138 YOLIBNNOD 31 41 UON YOLOW 4 ONT 100 0 28 td 2 ON 4 9N11002 90 28 43 NYA H311ASOMU3HL H3IVA LO 28 2431 W0123NNO2 X23H 90 28 3 UL ON 19138 NYS 9NI1002 10 26 ns 30 9 118 3010 1 208 t0123NN02 HOLIASOWN3HI p 32342 U
281. 31YA 90 28 0 28 80 28 8 Y L0 28 2 0N L ON 9 NOTLI3S pi ae er Eo E I em 4 8 i Dx SAT3002 antago LINN 13 SISONOYIO HILIASONUHL ain 3 8 90 28 50 28 69 6 n 3 3 EL 2H3 4 8 4 8 M 4 8 9 24189 31 10 4 ON 283 ta19 1 Yon 555 149771 2431 283 243 282 3384 cay sch 1 8 8 5 teu coi 0 28 0 x 0 1 5 4 81 8 1236 co 28 2 0N 81 8 N011235 44 033 AV138 NY3 49138 Nyd AY138 NY4 LIN 2931 9 1009 9 1002 ONT 1003 ivia NYE ox 9 1009 O QNO3 yiv HOLIAS NOLLINDI 3134 YSI a COO Ags D 0 ac 19 AUBLLYE 41871 1Y 23 70D WJLSAS NY4 ONI71009 2 4 WvHoVI ONIHIM 7 98D51626 Diagram Coolant Fan System 1993 RX 7 Wiring 13 Fig COOLING FAN CONTROL SYSTEM 1994 RX 7 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM DESCRIPTION To improve idle smoothness and engine reliability the cooling fan control system controls the electrical fan speed by ECM This system consists of the cooling fan cooling fan relays cooling fan control module ECM and input devices S Figs 14 and 15 ENGINE COOLANT TEMPER
282. 4A EL s 3 2 Do not replace converter if oil pan is full of 3 3 debris CALL MASH HOTLINE 3 3 3 2 3 accumulator is internal and not serviceable 3 3 CALL MASH HOTLINE 3 4 If cracked porous leakage damaged other CALL 3 3 MASH HOTLINE 3 U MAZDA AUTOMATIC TRANSMISSION APPLICATION TABLE 3 OF 6 UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 External Components NA4A EL RA4A EL 3 LJAA EL GF4A EL FAAA EL 3 3 NC4A EL 3 RBAA EL 3 3 G4A EL 3 3 3 P 3 RA4AX EL 7 3 GAAX ELD 7 AAAAAAAAAAAAAAAAAAAAAAAR AAA AAA AAA AAA AAA AAA AAR AAAAAAAAAAAAAAARAAAAAAA 3 Control valve body 3 RPL 3 RPL 3 RPL RPL RPL 3 AAAAAAAAAAAAAAAAAAAAA AAR AAA AAA AAA AAA AAA AAA AAAAAAAAAAAAAAAAAARAAAAAAA 3 Torque converter 2 3 RPL 3 RPL 3 RPL 3 RPL 3 RPL 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA Spool valve To ds o1 RP 5 RPT 5 A AAARAAAARAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Oil pump gasket 3 CMH 3 CMH CMH 5 RP RPL 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 5 Hydraulic governor E 3 lt 3 ci cem 4 AMAA AAAARAAAAAAAAAAARAAAAAR AAAAR AAAAR AAAARAAAAAAAAAAARAAAAR AAAARAARAR 3 Vacuum modulator RPL 3 3 ci t 3 n
283. 585 0000 80 0035 WB 525 3 AAAAAAAAAAAAAAAMAAAANAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAMAAAAAARARAARAAR 3 3 929 w w w 3 3 3 1988 95 3 3 3 All w o Cold 3 320 0000 80 0035 WB 550 3 Package 7 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1988 95 All with Cold 3 5857 0000 80 124F WB 700 3 Package 2 3 2 ARAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Milenia 1995 97 S All 3 490 0000 80 124F WB 700 3 AARAAAAARAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAARAAAAAAAAAAAAAA 3 B2000 3 3 1973 93 3 1982 84 3 All Except Diesel 7 375 0000 80 0024 WB 460 3 AAAAAAAAAAAAAAA AAA AA AAA AAA AAA AAA AA AAA AAA AAA AAAAAAAAAAAAAAAAAA 197 393 B2200 AAAAAAAAAAAKAAAAAAAAAAAAAABAAAAAAAA AAR ABAAAABAAAAAAAAAAAABAAA Optional For Above 375 3 0000 80 026R WB 525 3 Diesel 3 600 0000 80 0124 WB 675 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAA B3000 3 B4000 3 A 3 3 3 3 3 3 3 3 1994 97 3 B2300 B3000 Std Cab B2300 AAA AR 1994 97 3 3 1994 97 3 540 0000 80 58HD WB 582 3 B2300 B3000 3 650 0000 80 0065 WB 875 3 Opt Cold Spec 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
284. 7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM See Fig 1 battery tag TSD LOGISTICS MazDa DO NOT REMOVE TAG UNTIL RETAIL DELIVERY FAILURE TO COMPLETE THIS LOG MAY JEOPARDIZE WARRANTY CLAIM IDENTIFY AS MILL 626 MX6 ETC MODEL LAST 8 OF VIN LE SUITABLE 3 OR 4 LETTER OR NUMBER CODE SCHEDULED VOLTAGE CHECK CHECKER DATE VOLTAGE PORT OR DEALER STAFF MEMBER INITIALS FOR QUALITY TRACKING PURPOSES NOTES ON POSSIBLE REPLACE MENT BATTERY OR OTHER SPECIAL SERVICING FINAL V READING JUST PRIOR TO SHIPMENT TO DEALER V ON RECEIPT AT DEALER MMAWILL USE TO EVAULUATE PERFORMANCE OF THE SYSTEM INVENTORY MAINTENANCE VOLTAGE CHECK VOLTAGE AT TIME OF RETAIL DELIVERY CRITICAL MEASURE OF BATT CONDITION TO NEW RETAIL CUSTOMER VOLTAGE CHECK JUST PRIOR TO RETAIL DELIVERY NOTE TO DEALER CHECK AND NOTE IF BATTERY VOLTAGE IS LESS THAN 12 4 VOLTS 94D59900 AFTER SUITABLE CHARGE USE VAT 40 OR MIDTRONICS ELECTRONIC TESTER TO DIAGNOSE ACCORDING TO SERVICE BULLETIN 002 95 Fig 1 Battery Tag END OF ARTICLE NEW V4 0 NGS CARD AND REPROGRAMMING OF V2 02 CARD CAT ST NO 004 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 39PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN NEW V4 0 NGS CARD 49T0 88 01
285. 70 88 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 31PM CUSTOMER NOTE If the circuit breaker opens and stops operation of the wiper motor operation will resume once the circuit resets itself approx 5 minutes If while the circuit breaker is open the wiper switch is turned OFF the wiper will automatically move to the PARK position once the circuit breaker resets If the wiper motor stops while the vehicle is in motion Carefully guide the vehicle off the road and stop Turn the wiper switch OFF Wait approximately 5 minutes then turn the wiper switch ON to verify wiper operation If the wipers operate the wiper motor is functioning correctly circuit breaker opened momentarily TECHNICIAN S NOTE If the wiper motor DOES NOT operate check the wiper motor circuit Refer to Workshop Manual or specific model and replace wiper motor if necessary END OF ARTICLE FUSIBLE LINK REFERENCE CHART NO T 2 3 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 34PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN FUSIBLE LINK REFERENCE CHART Model All Mazda Date November 1 1990 Revised April 27 1992 No T 2 3 Group Parts Bulletin SERVICE INFORMATION For ea
286. 8 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM NOTE Be careful not to use another adhesive Install the hose white mark side within five minutes after applying adhesive NOTE Before installing the hose degrease the pipe for better adhesion Fuel Hose N32Z1 13 415 94F59332 Fig 53 Installing Hose on Inlet Side of Primary Fuel Distributor Submerging Hose End with White Mark into Adhesive 27 2 Install the clips on the hose of the inlet side of the primary fuel distributor NOTE Use two clips on the fuel distributor side Place the fuel distributor side clip claws on the top and the other one on the bottom For the directions of the clip claws see Figs 54 and 55 Insert the hose to the pipe bulge Match the edges of the clip and the hose end Replace all hose clips with new ones Do not use clips other than those included part number below Be careful not to place the clip on the pipe bulge Clip N32Z1 13 157 x 2pcs Protector N3B7 13 428A RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 38 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM Place the fuel distributor side clip claws on the top and the other one on the bottom 94659333 Insert the hose to the pipe bulge NO CLEARANCE Match th
287. 80 28 C2n3 1 8 2931 A78 81 8 NO11235 381983 300 WYLNOD NIYHIH3A0d uly V 318 1 4138 NYJ 24a 97 C ON 4 003 LLL 283 3 A 8 n31u 8 ROE C2W3 1 8 831478 e 283 MN313W VEL p 90 ac MOOK 1081N02 4 LNY1002 60 26 1 213 Ov Z 14312 0N NOISSTW3 1 3 INOU3 N33A139 YOLIINNOD 243 U0123NNO2 33283 90 28 0 3 1410 2 0N YOLORK N 4 1 1002 2W3 243 A 8 9 b 0N 3 NYS 1NY1003 243 243 a 1 t KILTASOWBJHL U31Y LO 28 243 HOLOW 4 1NY1002 143 NY 3 131071 28 3 n00W 710H1N02 11136 4 1005 243 56 9 poco 11 68 2 AY13U 4 1NY1002 20 28 3 4 2 0N UO10H NY3 1 1003 90 28 3 L ON YOLOW Nyd 2 50 8 AY138 NYJ I1NY3002 10 28 41 8 NO11935 4 C3NT9N3 NOI133S YOLI3NNOD NTT v1vO 99 1335 83141 IAHI LINN NIVYLB3AOJ 3 U31Y3H 1 0N AY338 NV4 1 003 1243 I 01 28 vo ec 1 21 28 20 vor 283 63 i ee ae 1 H Yo un aa 3 417 NY3 9N17002 Y09 3 A478 3 AVE A8U311Y8 W31SAS NV3 INV1009 2 8 MYHOVIG ONIHIM 7 98051628 Diagram Coolant Fan System 1994 RX 7 iring W Ty Fig END OF ARTICLE TURBO CHARGER BOLT PART NUMBER MT 06 13 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyr
288. 94 DESCRIPTION When shifting into 1st and or 2nd gear the shift movement may be stiff or binding may be felt This is caused by the chamfer on the tips of the clutch hub sleeve To improve the shift feeling since August 1 1993 production the chamfer on the tips of the clutch hub sleeves are formed using a press This process increases the accuracy and consistency of the chamfer REPAIR PROCEDURE 1 Verify the customer complaint 2 Replace the lst and 2nd clutch hub set and synchronizer ring according to the instructions in the appropriate service information PARTS INFORMATION TABLE k Part Number 3 Description 3 Qty Interchangeability 3 3 3 3 New 3 Old 3 3 3 z AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Rb5B23 17 260A R523 17 260 1 2 Clutch Hub Set 1 3 AN 3 WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty Warranty Type A Customer
289. 97 M 8 51 897 8 k i t 1 18 62 18 82 18 92 18 se 18 ve 18 8 I ents ssvare 893 H2118S tt 431238 984 uly 2 331138 aly S u S 4 d u 4 4 BATA 34004 BATYA JAVA 0 3 11745 30123CK1 80123081 u0133CNI 801230N1 OI0N310S 010N3105 01083105 01083108 BAIA 010N370S 34014 010N310S 010N310S ici e t t 62 18 92 18 L2 18 92 18 2 18 r 18 mere eta on om CER 1 431 wD aa o 43 d 178 Me 8 8 8 Ave A a cor a 112351 448 ae Ma 51 8 NOI133S Loa CCE CS 013 3 o ATY13U N1YM Ltt 83 G3 38 NIYM ava A a A 8 A a 8 na 193 178 4 8 1 8 nor W3lSAS 1OMINOO 3nd WALSAS 1081NOO ANIONS 8 WVHOVIC ONIHIM 7 98051625 amp Fuel Control System 1993 RX 7 ine iring Diagram Eng W E TRS sty KRE gt 5 m DD z TT lt o LL SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 44PM Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 1 8 664 2x31 ON NOISSIW3 t J11N0Hj N334138 YOLDINNOD t1 28 4 24312 0N NOISSIN3 Y 3 1NO S N334138 N0123NND2J 01 28 4 khouo t2w3 2 QN HOISSIN3 3 1N0H3 N33A138 YOLIBNNOD 31 41 UON YOLOW 4 ONT 100 0 28 td 2 ON 4 9N11002 90 28 43 NYA H311ASOMU3HL H3IVA LO 28 2431 W0123NNO2 X23H 90 28 3 UL ON 19138
290. 98 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 35PM 2 Select Ohm Meter on the tester and connect a test lead between the COM black and SIG red terminal on the NGS tester and note the reading A reading of O ohms indicates that the test lead and connections do not hav xcess resistance A reading other than O ohms may indicate a poor connection go to STEP 3 3 Disassemble the connectors and check for corrosion solder breakage or looseness Resolder connections to repair as necessary See Fig 2 4 Verify repair DISASSEMBLED VIEW OF CBS ASSEMBLED VIEW OF SCREW TYPE CONNECTOR SOLDER HERE DISCARD SCREW AR 98F54135 Fig 2 Assembeled Disassembled Connectors END OF ARTICLE MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN MAINTENANCE FREE BATTERY DIAGNOSTIC amp CHARGING PROCEDURE Model 5 All Mazda Models Category G Engine Electrical System Bulletin No 001 97 Date April 8 1997 NOTE This bulletin replaces the previously released bulletin Cat G No 002 95 dated April 5 1995 DESCRIPTION The information in thi
291. 98 Mitchell Repair Information Company LLC Saturday August 25 2001 10 02AM 94F54093 Fig 4 Positioning Shift Lever 2 Remove the shift lever 3 Remove th xtension housing installation bolts CAUTION When removing the extension housing be careful that the control lever is not pulled into or pushed against the shift rod gates 4 Lift up on and remove th xtension housing from the center housing PAGE J 59 PPF INSPECTION DIMENSIONS PROVIDED Measure the distance from the bottom of the front tunnel reinforcement to the point directly above it on the PPF See Fig 5 Standard 77 1 mm 3 04 in Acceptable Range 72 79 mm 2 83 3 11 in CAUTION If the distance is not within the acceptable range readjust the PPF 94G54094 Fig 5 PPF Measurement END OF ARTICLE 1ST AND 2ND GEAR HARD TO SHIFT IMPROVED CLUTCH HUB CAT J NO 002 94 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 17AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN 1st AND 2nd GEAR HARD TO SHIFT Model 5 Mazda RX 7 1993 Vehicles with a VIN of JMIFD PO200001 through JMIFD R0299999 1994 Vehicles with a VIN of JMIFD R0300001 through JMIFD R0300031 NOTE The asterisk in the VIN range can be any number 0 through 9 or X Category J Bulletin No 002 94 Date 1 20
292. 98 Mitchell Repair Information Company LLC Saturday August 25 2001 10 23AM gear CAUTION DO NOT keep the steering wheel fully turned to the locked position for more than five seconds Power steering system damage may occur Power Steering Gear Boot Wire Inspect For Fluid Leakage 97A54353 Fig 1 Power Steering Gear amp Boot Wire Inspect Fluid Leakage END OF ARTICLE FRONT SUSPENSION UPPER ARM BUSHING NOISE CAT R NO 004 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 23AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN FRONT UPPER BUSHING NOISE Model 1993 Mazda RX 7 Category R No 004 93 Date 9 22 93 Category R No 93 02 Date Sept 93 APPLICABLE MODELS Model 3 Year 3 VIN Range 5 Mazda RX 7 3 1993 3 JMIFD33 P0200001 through JM1FD33 P0204513
293. 98H51745 Fig 15 Cooling Fan Control System Operation SYSTEM INSPECTION 1 Verify that the engine coolant temperature is below 800C 1769 F 2 Turn the ignition switch to ON for 15 seconds or longer 3 Turn the ignition switch to OFF 4 Ground the check connector by using a jumper wire 5 Turn the ignition switch to ON and verify that the cooling fan operates approximately 100 150 seconds after the ignition switch is turned to ON 6 If the cooling fan will not operate inspect the following Battery positive voltage Fan control signal Engine coolant temperature signal Ground SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 19 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 45PM 7 Turn the ignition switch to OFF 8 Verify that the cooling fan keep operating after the ignition switch is turned to OFF 9 If not replace the cooling fan control module See Fig 5 10 Wait for approximately 20 seconds 11 Disconnect cooling fan relay connector A Verify that the cooling fan operates at low speed See Fig 6 12 If not inspect the cooling fan relay 13 Connect cooling fan relay connector A Verify that the cooling fan operates at the speed before connector A is disconnected 14 Disconn
294. 992 95 626 MX 6 3 A1 3 9 mm 3 E A E RE RU 5 3 1992 95 929 3 Ll mm A AAARRARARARARAAAAAAAAARAAARAAAAAAAAAAAARKAAAAAAAAAAAAR 3 4 x 2 3 L3 mm 3 3 1989 95 MPV AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 4 x 4 3 2 mm 3 E 1990 95 MX 5 Miata 3 A 3 LO mm 3 3 AARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1995 Millenia 3 A 3 10 mm 3 U WARRANTY INFORMATION Applies To Verified Customer Complaints On Vehicles Covered Under Normal Warranty Refer To The SRT Microfiche For Current Warranty Term Information Warranty Type O Symptom Code 30 Damage Code 9H Part Number Main Cause 5555 FE 001 Operation Number XX0640RX Labor Hours 0 5 Hrs END OF ARTICLE WHEEL BALANCE TIPS FOR HIGHER PRECISION RESULTS MT 0897 08 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 25AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER WHEEL BALANCE Model 5 All Mazda Model Category Mazda Tips Bulletin No MT 0897 08 Date August 1997 DESCRIPTION Use the following hints for customer complaints which require a higher precision whee
295. 993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 24AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN BRAKE JUDDER REPAIR Model 5 1983 95 Mazda Vehicles Canadian Category P Brakes Bulletin No 95 02 Date May 1995 NOTE This bulletin supersedes Service Bulletin Cat P No 94 06 DESCRIPTION Customers who complain of vibration or pulsation in the steering wheel brake pedal floor or seat while applying the brakes may be experiencing symptoms of brake judder Judder is caused by Disk Thickness Variation DTV rotor run out and or rotor surface rust which leads to DTV This bulletin describes the causes and corrections for each condition CAUSES OF JUDDER 1 Disc Thickness Variation DTV DTV creates a vibration pulsation during application of the brakes DTV will increase with distance travelled if the run out of the disc is excessive 2 Disc Rotor Run Out Run out or rotor wobble leads to DTV It is corrected by precision machining to bring the run out within Specification 3 Rotor Surface Rust Under certain conditions storage or use in extreme environments the surface of the brake rotors may become rusted in the pad non contact area If this corrosion penetrates the rotor surface deeply enough it will not wear or rub off during normal use This will cause DTV COR
296. AA 3 3 3 3 Rep always replace the SAS or lacement will operational Use the tabl le below to PARTS REPLACEMENT AFTER AIRBAG DEPLOYMENT CAT T NO 007 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 40PM 1993 MPV incorporated air bag systems during a mid year production change w w www xx 1992 RX 7 convertibles were available only PNE ne AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 3 3 3 3 END OF ARTICLE POOR WIPER BLADE PERFORMANCE CAT A NO 93 07 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 40PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WIPER BLADE PERFORMANCE Model All Mazda Models Category A Bulletin No 93 07 Date August 1993 SPECIAL ATTENTION ALL P D I Service Technicians DESCRIPTION Results from the Certified Delivery Program have revealed that there are a large number of customer complaints about wiper blade performance The complaints usually relate to one of the following three problems see Fig 1 Streaking Chattering blade hopping Partial cleaning Streaking Partial cleaning Blade hopping 94650233 Fig 1 Wiper Blade Complaints INSPECTION REPAIR PROCEDURE During the
297. AAA B4000 Cab Plus 3 850 0000 80 0065 WB 875 3 AAA AAAAAAAAAAAAAAAAAAAR AAAAAAAAAA AAAAAAAAAA A AAAAAAAAAAAAAAAAAARAAAAA B2600 3 1989 93 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1987 88 All 3 310 0000 80 0024 WB 460 All B2600 3 320 0000 80 026R WB 525 B2600i A 3 3 3 3 3 3 1987 88 3 Optional For Above 390 0000 80 224F WB 525 3 AAAAAAAAAAAAAKAAAAAAAAAAAAAAANAKARAAAAAAAAAAAAAADARAAAAAAARRARAAAA ARK 3 Navajo 3 991 94 3 A 3 650 0000 80 0065 WB 875 3 AKAAKAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA i 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 MPV 3 97 3 Optional Cold 3 585 3 0000 80 124F WB 700 3 3 3 3 Package 3 3 3 3 U WARRANTABLE CHARGING AND OR REPLACEMENT The information below outl that is covered under vehic ines when battery charging or replacement e warranty MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright
298. AAA END OF ARTICLE HIGH STEERING WHEEL EFFORT VERIFY CONDITION MT 0995 05 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 23AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN STEERING WHEEL EFFORT Model 5 All Mazda Category Mazda Tips Bulletin No MT 0995 05 Date 1995 DESCRIPTION If a customer complains of high or uneven steering effort before attempting any repair verify the amount of force required to turn the steering wheel Use the instructions in the Workshop Manual category N under Steering Wheel Effort This procedure involves using a pull scale CAUTION Before measuring steering wheel effort make sure that Tires are the correct size and correctly inflated 2 Power steering fluid level and condition are OK 3 Vehicle is on a hard level sur ace for testing If the force is within the specification listed in the Workshop Manual inform the customer that this is a normal condition d h f the force is out of specification and or abnormally igh then troubleshoot per the Workshop Manual END OF ARTICLE INSTALLATION OF TIRE CHAINS CAT Q NO 005 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 23AM ARTICLE BEGINNING TECHNICAL
299. AAAA 3 Drums 3 CMH 3 CMH 3 CMH 3 CMH AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Brakes 3 CMH 3 CMH 3 CMH 3 CMH 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Park pawl 3 CMH 3 CMH 3 CMH 3 CMH ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Int linkage CMH CMH CMH 3 CMH 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Hydraulic governor 3 CMH 3 CMH 3 S ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 7 Servo pistons CMH 3 CMH 2 CMA 3 4 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Differential 3 3 CMH 3 m 3 3 2 3 Accumulator 3 3 3 m 3 3 A AAAARAAAAAAAAARARAAAAAAARARAAAARAAAARAAAARAAAAAAAAAAA 3 T C Housing 4 3 CMH 3 CMH 3 CMH 3 CMH ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Main case 4 E CMH 3 CMH 3 CMH 3 CMH 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 ADJ Adjust as needed per W M authorization not 3 3 required s 3 RPL Repair or replace as needed per W M 3 authorization not required 3 CMH Call MASH Hotline for REMAN ASSEMBLY 3 3 authorization do not repair or replace 3 3 component 3 3 1 Throttle cable not used on GF4A EL 3 3 2 Do not replace converter if oil pan is full of 3 3
300. AAAAAAA 3 Complete 4 7 Hot Line E 3 Check Sheet Instruction 3 3 Order Part Authorized 3 AAAAAAAAAAAAAAU Replacement 3 3 Auth No Required AAAAAAAAAAAU UAAAAAAAAAAAAAAAAAAA Review Receive Parts 3 Diagnostics 3 UAAAAAAAAAAAAAAAA 3 Return Replacement 3 Part With Check 3 3 Sheet To Your I 3 Servicing PDC 3 3 3 Warranty Claim 3 2 Application 3 SECTION 4 CHARGING SYSTEM DIAGNOSTIC PROCEDURES ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM 1 Start the engine and confirm that the alternator warning light is not illuminating NOTE If the warning light is illuminated see Fig 9 the self diagnosis operation is functioning Check the alternator and related harness according to appropriate service information 94D53036 LCHARGE Fig 9 Charge Indicator Light 2 Fluctuate th ngine RPM and listen for alternator bearing or engine belt noise If noise is present inspect for loose or damaged belt or damage to the
301. AAAAAAA Instruction 3 3 3 Order Part Authorized AAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAU Replacement 3 3 3 Auth No Required AAAAAAAAAAAU AAAAAAAAAAAAAAAAAAA Review 3 Receive Parts 3 Diagnostics U UA 3 3 3 AA UA 3 3 AA 3 Keep Check Sheets At Dealer 3 Attach to R O 3 3 Warranty Claim 3 Application 3 SECTION 3 FUEL PUMP DIAGNOSTIC PROCEDURES 1 Disconnect negative terminal and check battery voltage Voltage should be 12 4V or more Reconnect terminal 2 Start engine and run at idle ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM 3 Disconnect circuit opening relay Engine will continue to run until all fuel in the supply line is used WARNING Step 3 is designed to eliminate fuel in the supply line and nable safe installation of the fuel pressure gauge Refer to the appropriate service information for further instructions 4 Disconnect the negative battery terminal 5 Install the fue
302. AAAAAAAAAAA 3 9994 00 600 3 Nut Flange 3 3 WARRANTY INFORMATION Apples to verified customer complaints on vehicles covered under normal warranty Refer to the SRT microfiche for warranty term information Warranty Type A Symptom Code 80 Damage Code 9G Part Number Main Cause F285 13 363 Quantity 1 Operation No XX921XRX Labor Time 0 2 hr END OF ARTICLE REPLACEMENT BUMPERS GREASE REMOVAL PRECAUTIONS MT 08 03 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 40AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN REPLACEMENT FRONT AND REAR BUMPERS Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 08 03 Date 1995 DESCRIPTION On current parts in PDC stock if a grease remover is used on a replacement front or rear bumper the primer may rub off As you may know grease remover is normally used prior to painting the bumper If the primer rubs off the bumper must be re primed prior to painting We recommend that all grease remover products that contain Naptha solvents such as PPG DX33C should not be used Instead a mixture of 50 Isopropyl Alcohol and 50 water PPG DX103 or equivalent should be used as a grease remover Please convey this information
303. AAAAAAAAAAA AAAAAAAAAAAAAAU 3 MMA 3 AAAAAAAAAAAAAAAA 3 3 Results AA No Trouble A Contact Region AAA Found 3 Hot Line 3 3 AAAAAAAAAAAAAAAAAU gt Trouble Found 3 _ 3 3 3 AAAAAAAAAAAAAAAA 3 Complete 4 7 Hot Line E 3 Check Sheet Instruction 3 3 Order Part Authorized 3 AAAAAAAAAAAAAAU Replacement 3 3 Auth No Required AAAAAAAAAAAU UAAAAAAAAAAAAAAAAAAA Review Receive Parts 3 Diagnostics 3 UAAAAAAAAAAAAAAAA 3 Return Replacement 3 Part With Check 3 3 Sheet To Your I 3 Servicing PDC 3 3 3 Warranty Claim 3 2 Application 3 SECTION 4 CHARGING SYSTEM DIAGNOSTIC PROCEDURES ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM 1 Start the engine and confirm that the alternator warning light is not illuminating NOTE If the warning light is illuminated see Fig 9 the self diagnosis operati
304. AAAAAAAAAAAA N315 16 460B N315 16 460A Clutch Disc 3 de a AN 5 AAAAAAAAAAAAAA AAAAAAAAAAAAA AAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAA 3 Interchangeability AN New and old parts are fully interchangeable AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAU END OF ARTICLE DTC DIAGNOSTIC TROUBLE SHOOTING TIPS MT 0597 07 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 18AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER DTC DIAGNOSTICS Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0597 07 Date May 1997 DESCRIPTION The diagnostic procedures for DTCs Diagnostic Trouble Codes in the Workshop manual don t always include the procedure to check related connectors that are within the DTC component s circuit Whenever performing diagnostic procedures always use the wiring diagram in conjunction with the Workshop Manual Check each related connector for the following Incomplete connection Loos ma terminals Terminals that are pushed out of their connectors Water inside the connector Terminal corrosion Also check each related harness for damage END OF ARTICLE REMANUFACTURED TRANS CANADIAN DIAGNOSIS SHEET CAT J NO 95 02 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair
305. AAAAAAAAAAAAAAAAA NO U 3 Green OK To Test Light ON AAAAAA Battery Has Less Than 10 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU Volts Recharge Once amp 3 YES ONERE Cu Lo en 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 Battery Has At Least 10 2V 3 3 Dial in Rated CCA And Read 3 MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM 3 Condition Scale Of The Meter U RED REPLACE 3 Meter shows Good or Replace AAAAAAAAAAAAAAAAA A U 3 GREEN 3 Replace Battery 3 GOOD 3 Switch to C Position To 3 3 Check Voltage 3
306. AAAAAAAAAAAAAAAAAAA 3 1995 3 6 3 3 3 1 3 1 3 2 3 i 3 3 3 3 3 RX 7 3 3 3 3 3 3 3 3 3 3 RA RARARAARRAAAAARAARAAARAAAAARAAARAARAAARARAAARAAAAAARAAARAAAAARAAAR 3 1989 93 3 3 3 3 dl 3 3 3 3 2 3 3 3 3 3 3 MPV S 3 3 3 3 3 3 3 3 3 3 RARRRARARARRRRRRRRRRRARRRRRRRRRRRRRRRRRARRRRRARRRRRARRRRRRRRRRRRRRRRR 3 1994 3 3 3 3 1 3 2 3 1 3 1 3 ah 3 3 3 3 3 MPV S 3 3 3 3 3 3 3 3 3 3 3 3 1988 92 3 5 3 3 3 2 3 1 3 3 3 3 3 3 3 3 626 MX 63 3 3 3 3 3 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAARAAAAAA 31993 94 3 5 3 3 3 2 3 3 3 3 3 3 3 3 3 626 MX 63 3 3 3 3 3 3 3 3 3 RAARARARAARRARAAARAARAAARAAARARAAARAARAAARARAAARAAAAAARAAARAAAAARAAAR 3 1990 93 3 3 3 4 3 2 3 3 4 3 3 3 3 3 3 B Series 3 3 3 3 3 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAARAAAAAAAARAARAAA 3 1994 3 3 3 3 3 3 3 3 A 3 3 3 3 B Series 3 3 3 3 3 3 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAARAAAAAAAARAARAAR 3 1991 943 3 3 3 3 3 3 3 3 A 3 3 3 3 Navajo 3 3 3 3 3 3 3 3 3 3 3 3 NOTE Pa
307. AAAAAAAAAAAAAAAAAAAAA 3 3 3 Navajo 13393 and prior R12 ESHM2C31A2 A AAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA uunc and after R134a 7 NSHMIC23IB d AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA B Series Built before Sep 20 1993 7 ESHM2C31A2 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 A Built after Sep 20 1993 R134a 7 WSHMIC231B AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU END OF ARTICLE USE OF 12 REFRIGERANT SUBSTITUTES CAT U NO 009 96 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 10AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN USE OF R 12 REFRIGERANT SUBSTITUTES Model 5 All Mazda Models Category U Heater and Air Conditioning Systems Bulletin 009 96 Date October 21 1996 DESCRIPTION Mazda Corporation does not approve of using substitute R 12 refrigerants when an A C system requires charging Use of these products may result in component damage and loss of warranty If service is required on a vehicle with an R 12 system use only new or known good recycled refrigerant NOTE A C systems designed to operate on R 134a can be recharged using only HFC 134a Using R 12 substitutes may result ina hazardous condition and
308. AAAAAAAAAAAAAAAAAAAAAAAA 3 Battery Voltage Load Test 3 3 3 According to Service Bulletin instructions Category No According to DSM or Hot Line Authorization Authorization Other Repair Type Warranty Customer Pay Technician s Signature Date UAAAKAAAAAAAAAAAAAAARAAAAAAAAAAAAAAABAAAABAAAAAAAAAAAAAL 3 MELA Comments ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM 3 3 3 3 3 3 3 3 3 Signature Date 3 AAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU SECTION 5 WARRANTY INFORMATION Symptom Code Complete Applicable Code Damage Code Complete Applicable Code Part Number Main Cause Complete Applicable Part Number OPERATION NUMBER AND LABOR HOURS TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 7 3 Operation Number 7 Labor Hours 3 Engine Control Unit ECU Diagnosi
309. AAAAAAAAAAAAAAAAAAAAAAAAA WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 21 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM 1 Are there any poor Yes Repair or Replace connector 3 connections at solenoid 3 valve and EC AT control 3 unit connectors 3 No 3 Go to next step AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Disconnect 16 pin EC AT 3 Yes Go to next step 2 3 control unit connector 3 3 3 Is resistance between 1F A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 terminal solenoid valve 3 No 3 Go to Step 4 7 line pressure and ground 3 3 7 3 OK 3 3 3 3 Resistance 2 5 5 0 ohms 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Disconnect 16 pin EC AT 3 Yes Go to Step 5 2 3 control unit connector 3 j 3 3 Is resistance between 1H A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA terminal dropping 3 No 3 Go to Step 7 2 3 resistor and ground OK 3 3 3 3 Resistance 12 5 19 0 ohms 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 3 Disconnect solenoid 3 Yes Check wiring and connectors 3 3 connector 3 from EC AT control unit to 3 Is
310. AAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 3 External linkage 3 ADJ 3 ADJ 3 ADJ ADJ ADJ ARAAAAAAAARAAAARAAAARARAARARAARARAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAA ADJ Adjust as needed per W M authorization not required s 3 RPL Repair or replace as needed per W M authorization not 3 3 required 3 3 CMH Call MASH Hotline for REMAN ASSEMBLY authorization do not 3 3 repair or replace component 2 3 1 Throttle cable not used on GF4A EL 3 3 2 Do not replace converter if oil pan is full of debris CALL 3 MASH HOTLINE 3 3 3 2 3 accumulator is internal and not serviceable CALL MASH 3 3 HOTLINE 3 3 4 If cracked porous leakage damaged other CALL MASH E 3 HOTLINE 3 DDR UM EUM m E ut UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA External Adjustments NA4A HL LA4A EL A4LD 4R44E 3 3 3 3 3 3 AR55E 3 AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Satu
311. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAA AAAARAA 3 Part d 3 LB5 3 LB52 LB53 LB54 LB55 3 LB56 LB57 3 ZZLO 61 J19 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 3 61J1X 61J1X3 61J1X 61J1X 61J1X 61J1X 611411 3 KIT ARAAAAAAAARAAAAAAARARAARARARAARAAAAAAAAARARAARARAAAAAAARARARAARARAAAAA O ring Quantity Per Vehicle 2 3 1989 94 3 3 3 3 3 3 3 3 3 3 3 323 3 5 3 3 3 B 3 3 2 3 3 3 3 3 3 Protege 3 3 3 3 3 3 3 3 3 RAARARAAAARRAAAAARAARAAARAAARARAAARAARAAAAAAAAARAAAAAARAAARAAAAARAAAR 3 1992 94 3 5 3 3 3 3 3 3 3 3 3 3 3 3 3 MX 3 3 3 3 3 3 3 3 3 3 AAAAAAAAAAAAAAAARAAAAAAAAAAAAANAAAAAAAARAAAAAAAAAAAAAAAAAAAAAARAAAAAA 3 1990 93 3 A 3 3 3 3 3 3 3 3 3 3 3 3 x 5 3 3 3 3 3 3 3 3 3 3 1994 3 A 3 3 1 3 1 3 2 3 1 3 3 3 3 MX 5 3 3 3 3 3 3 3 3 3 AAAAAAAARAAAAAAAAAAAAAAARAAAAAAAAARAAAAAARAARAAAAAAARARAAAAAARAAAAAAA 3 1989 94 3 6 3 3 3 2 3 3 3 3 3 3 3 3 3 RX 7 3 3 3 3 3 3 3 3 3 3 3 AANAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAARAAAAAAAARAAAAAR 3 3 A C O RING REPLACEMENT GUIDE CAT U NO 001 94 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
312. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Step Inspection 3 Action 7 3 1 3 Are there any poor 3 Yes Repair or Replace connector 3 3 connections at solenoid 3 7 3 3 valve and FC AT control AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 unit connectors 3 No 3 Go to next step 2 ARAAAAAAAARAARARAARARAAAARARAARARAAAAAARAAAAAAAAAAAAAARAAAAAARARAAAAA 2 Connect a circuit tester 3 Yes Check wiring and go to 3 to terminals 1B and ground 3 Step 5 as shown in Fig 11 3 3 2 Is output voltage of 2 solenoid valve shift B AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA w w www iw w w www at EC AT control unit OK Go to next step 2 Acceptable Voltages 3 3 Battery voltage 1st 2nd 3 3 3 gear 3 3 3 Below volt 3rd 0 D gear 3 AARAAAAAAAAARARAAAARAAAAAAAAAAAAAARARAAAARAAAARAAAARARAAAARAAAARAAAAAC 3 3 Disconnect 16 pin EC AT 3 Yes Go to Step 5 3 control unit connector 3 I 3 3 Is resistance between 1B WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Re
313. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA P White Industries E 01055 i 3 Div of K Whit Tools 3 3 Inc 3 7 AAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAA AAAA AAAAAAAAAAAAA AAAAAAAAAAAAAAAU NOTE A UL Multiple Listing referred to as private labeling by the industry is the formal publication of the name of company that appears on equipment that is basically UL Listed for another company It would be similar to a private brand except that the basic company name need not appear anywhere on the product This equipment has been evaluated to determine the minimum purity specifications for recycled CFC 12 for use in mobile automotive air conditions systems Such equipment is provided with the following auxiliary marking Design Certified by Underwriters Laboratories for Compliance with date to HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM indicate that the equipment has been investigated for compliance with the applicable SAE requirements TABLE 4 SUBSTANTIALLY IDENTICAL RECOVER ONLY EQUIPMENT TABLE 4 SUBSTANTIALLY IDENTICAL RECOVER ONLY EQUIPMENT UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAY 3 NONE APPROVED AT THIS TIME 3
314. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 6 3 Disconnect speed sensor 2 Yes Go to next step 3 j 3 connector and connect 2 3 circuit tester 3 3 Does pointer of circuit E 3 tester move slightly when No Replace speed sensor 2 3 7 3 driven gear is slowly j 2 turned B 2 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 No Replace sensor 2 A 7 3 Disconnect speed sensor 2 Yes Check wiring and connectors 3 3 3 connector 3 3 from speed sensor 2 to 3 3 Is continuity of sensor OK 1 OGRET 3 3 Resistance 3 If OK go to next step 3 3 approx 290 Ohms at 3 3 If not OK repair wiring 2 3 3 208C 680 3 3 and or connector 3 3 3 A 3 3 3 WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM 8 Disconnect negative 3 Yes Replace EC AT control unit 2 battery cable
315. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Output Amperage z AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Instrument Used 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Battery Voltage Open Terminal 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Battery Voltage Load Test 3 3 3 According to Service Bulletin instructions Category No According to DSM or Hot Line Authorization Authorization Other Repair Type Warranty Customer Pay Technician s Signature Date UAAAKAAAAAAAAAAAAAAARAAAAAAAAAAAAAAABAAAABAAAAAAAAAAAAAL 3 MELA Comments ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM 3 3 3 3 3 3 3 3 3 Signature Date 3 AAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU SECTION 5 WARRANTY INFORMATION Symptom Code Complete Applicable Code Damage Code Complete Applicable Code Part Number Main Cause Complete Applicable Part Number OPERATION NUMBER AND LABOR HOURS TABLE AAAAAAAAAAAAAAA
316. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Yes Replace EC AT control unit 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3No Intermittent poor connection 3 5 Check for cause 3 3 3 3 U WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 19 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM EC AT CONTROL UNIT SOLENOID CONNECTOR OVERRUNNING CLUTCH 94155432 Fig 12 Service Code 62 Circuit Diagram SERVICE CODE 63 DIAGNOSTIC TABLE UAAAAAAAAAAAAAAAAAAABAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAARAL 3 Service Code No 63 Solenoid valve Lockup AAAAAAAAAAAAAAAAAAAAAAAAAAA AAA AAA AAA AAA AAA AAA AAAAAAAAAAAAAAAAAAAAAAAA 3 Step Inspection 3 Action AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1 Are there any poor Yes Repair or Replace connector 3 3 connections at solenoid I 3 3 valve and EC AT control unit connectors 3 No Go to next step AA
317. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 7 3 Operation Number 7 Labor Hours 3 Engine Control Unit ECU Diagnosis F0005XDX 3 0 9 3 3 Air Flow Sensor AFM Diagnosis 3 F0006XDX 3 0 4 3 3 Fuel Pump Diagnosis 1 F0007XDX 0 5 3 3 Charging System Diagnosis G0003XDX 3 1 4 7 3 NOTE Labor hours shown are the maximum allowable time Claim 3 only the actual time used for these operations AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
318. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU w w www ARS PR e wy U 3 External Adjustments NA4A EL RA4A EL 3 LJA4A EL GF4A EL FA4A EL 3 3 NC4A EL RB4A EL 3 G4A EL 3 3 3 3 RA4AX EL 3 3 GAAX EL 1 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 2 4 band 3 ADJ 3 ADJ 3 ADJ ADJ ADJ AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 OD band 3 ADJ 3 3 3 3 A AARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 INT band 3 LAT 3 3 3 3 pees 3 A RAARAAAAAAAAAAAARAAAAAAARAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Low Rev band 3 3 3 7 3 m 4 A RAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAA 3 T R sensor 3 ADJ 3 ADJ 3 ADJ ADJ ADJ 3 Throttle cable 3 i 3 ADJ 1 3 ADJ 3 3 pressure 3 3 3 2 Modulator pin ADJ 7 3 Y SS
319. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 N3Z1 15 S10B N3Z1 15 S10B 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 N3A1 13 S60 3 N3A1 13 S60 3 I ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 N3C1 15 173 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 N3Z 5 S20 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 All Quantities All Quantities All Quantities 3 3 are 1 3 are 1 are 1 END ARTICLE SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL REPAIRS Model 5 1993 94 Mazda RX 7 Category AD Bulletin No 002 96 Date February 1996 PURPOSE OF THIS INFORMATION 1 Emphasize the importance of proper repair 2 Provide diagnostic tips if repairs are not performed correctly CONTENTS January 1994 M Tips contents related to this recall General Driveability and Component Troubleshooting Tips Service Bulletin AD 00
320. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AY Flexibilized Deltron or Concept Topcoat System AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAU 1 On rigid plastic parts no flexible additives are necessary 2 Optional The use of this product is recommended for maximum performance 3 This product must be sealed when using any black topcoat system DPX 801 should only be used over bare plastic or flexible repair material with minimal overlap END OF ARTICLE RATTLING FROM DASHBOARD AT IDLE W BRAKES APPLIED CAT S NO 011 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RATTLING NOISE FROM DASHBOARD AT IDLE WITH BRAKES APPLIED Model 1993 95 Mazda RX 7 Category S Body Bulletin No 011 97 Date May 19 1997 DESCRIPTION A rattling noise may be heard from the dashboard when pressing the brake pedal at idle This noise is transmitted through the body by the check valve operating in the brake vacuum line Customers complaining of this noise should have the vehicle inspect
321. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 3 3 3 3 3 3 3 3 No fast idle 3 Check the idle speed control valve connector for good connection 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 Excess fuel consumption Improper vacuum may result in faulty after recall repair 3 fuel regulator operation 3 work 3 Check fuel regulator vacuum hose 2 connection 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 3 3 Unusual air noise from If the Air Control Valve check valve center of engine just is not properly seated the ACV can off idle 3 not seat properly 3 3 Check that the ACV check valve is SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM w 3 properly installed 3 AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Cooling fan will not 3 If the cooling fan will not operate 3 3 3 3 3 operate 3 under any conditions during the fan 3 test 3 3 3 3 Check the wire harness ground 2 strap for proper connection
322. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 END OF ARTICLE EMISSION INSPECTION MAINTENANCE TEST PREPARATIONS CAT F NO 005 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 59AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PROPER PREPARATION FOR STATE EMISSION INSPECTION AND MAINTENANCE TEST Model All Mazda Models Category F Bulletin No 005 93 Date April 28 1993 DESCRIPTION Some vehicles with properly functioning emission control systems may fail certain states emission inspection and maintenance test s tailpipe emission tests In order to avoid the above mentioned condition make sure the following items are observed before conducting the test Engine should be warmed up but not overheating as indicated by gauge or warning light All electrical loads and AC should be turned off For 5 speed models Neutral range should be selected For automatic transmission models N or P range should be selected NOTE All Mazda vehicles meet the U S EPA and California emission standards when tested under the EPA certification test procedure PREPARATION PROCEDURE Perform the following before conducting the emission inspection and maintenance test Before testing bring the engine s operating temperature to normal by operating the engi
323. AAAAAAAAAAAAAAAAAAAAAAAAAAARAAAANABAAAAARAAAAAAAAARARAAAA Cleaner recycles its solvent Mor xpensiv Does not require Requires more storage space the disposal of flushing solvent after each procedure Requires periodic filter and solvent replacement Solvent cannot be dumped in shop drain Requires only 5 gal of flushing solvent which can be used for several flushing procedures Dealer must consult state and local authorities for proper disposal of waste Easier to use Does not require shop air and air hoses for flushing procedure w w www ww G G G www w 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Also cleans torque converters 2002 NP SER RE PRICING INFORMATION PRICING INFORMATION TABLE 3 Manufacturer Model 3 Price 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Kent Moore J35944 MAZ A T Oil 9212 55 3 3 Cooler and Line Flusher 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 OTC 60081 M Portable Oil 3 541 00 3 Cooler Torque Converter 3 3 Cleaner 3 5
324. AAAAAAAAAAAAAAAAAAAAAAARAAA AAA 7 Control valve body 3 RPL 3 RPL 3 RPL RPL 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Torque converter 2 3 RPL 3 RPL 3 RPL 3 RPL 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAA P Spool valve 3 3 ao 3 A RAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Oil pump gasket 3 CMH e RPL CMH 3 CMH 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA P Hydraulic governor CMH 3 3 CMH 3 7 Vacuum modulator 4 RPL 3 3 RPL 3 EE e AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Front seal 3 RPL J RPL 3 RPL 3 RPL AAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAA gt Ext hsg seal 3 RPL 3 36 5 AARAAAAAAAAAAAARAARAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Pan gasket RPL j RPL RPL 3 RPL 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Axle seals 3 RPL 3 3 3 Oil filter strainer 3 RPL 3 CMH 3 RPL 3
325. AAAAAAAAAAAAAAAAAAU AAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 YES 3 Measure Open Circuit 3 Voltage Of Battery 3 AAAAAAAAAAAAAAAAAAAAAAAU AAAAAAAAA AAAAAAAAAAAAA NO UAAAAAAAAAAAAAAKA 3 Battery Voltage 12 4V AAAAA Charge Battery 3 or Above 3 U 3 AXES 3 Battery OK 3 U NOTE Quick Change battery by setting the charge rate at the Highest or Boost position When testing in the vehicle turn the headlights ON for 15 seconds to remove the surface charge before testing CAUTION DO NOT boost or quick charge MX 5 Miata Gel type batteries MIDTRONICS POWER SENSOR PLUS TESTER 1 Connect the Midtronics Power Sensor Plus tester If low voltage is found less than 10 2V charge the battery for two 2 hours and recheck If the voltage is greater than 10 2V test battery condition without precharging If low voltage is still found after a two 2 hour charge replace the battery according to the information in the warranty section of this bulletin 2 If the tester indicates that the battery is not at fault refer to the appropriate workshop manual or BETM Body Electrical
326. AAAAAAAAAAAAAG 2 Inspect Oil for x 3 Contamination 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 Contamination 3 Replace 3 AAAAAAAA gt AAAAAAAA Present Part AA gt A Receiver Drier 3 3 3 3 icles of Metal AAAAAAAAAAAAAAAAAU or O Ring 7 AAAAAAAAAAAAAAAAAU 0 No Obvious Contamination AAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAA AAAAAAAAAAAAR Do Not Replace the 3 3 Receiver Drier Continue 3 To Use Original ARAAAAAAAAAAAAAAAAAAAAAAAAAU CAUTION Before charging always evacuate the A C system thoroughly to remove air and moisture Use a vacuum pump to evacuate the system Hold vacuum at 29 inches 740mm Hg for 5 10 minutes END OF ARTICLE RECEIVER DRIER REPLACEMENT CRITERIA INFORMATION CAT U NO 001 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 09AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RECEIVER DRIVER REPLACEMENT CRITERIA WHEN REPLACING OTHER A C COMPONENTS Model 5 All Mazda Models with A C Category U Heater and Air Conditioner Systems Bulletin No 001 95 Date February 15 1995 APPLICABLE MODELS VINS All models equipped with R12 and R134a Except Navajo and 1994 and
327. AAAAAAAAAAU UAAAAAAAAAAAAAAU 3 3 DRIVEABILITY 3 3 UNUSUAL ABNORMAL 3 U 3 NOISE I 3 AAU AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM 3 Record Mechanical System 3 Visually Inspect Fluid 3 Test amp Line Pressure On 2 Level Check For 3 3 Check Sheet Use Trans 3 3 Particles 3 3 Tester For LA4A EL 3 U 3 UAAAAAAAAAAAAAAAAAAAA A Diagnose amp Isolate The _ 3 Record Location Of Noise 3 Problem Use Quick 1 A AAAAAAAAAAAAAAAAAAAAAAAARAU Diagnostic Chart II From 3 3 3 WSM 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAARAU 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAA
328. AAAAAARAA Pulse generator 3 3 RPL ara wee oRBLRS 3 ARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAARAA ATF thermo sensor 3 RPL 3 RPL RPL 3 RPL 3 RPL 3 ARAAAAAARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Accumulators EM 3 RPL 3 RPL 7 RPL 3 CMH 3 ARAAAAAARARAAAARARAARAAAARARAAAAAARARAAAARARAARAAAARAAARAAAAAAAAAAAA ADJ Adjust as needed per W M authorization not required 3 3 RPL Repair or replace as needed per W M authorization not 3 3 required 3 3 CMH Call MASH Hotline for REMAN ASSEMBLY authorization do not 3 3 repair or replace component 2 3 1 Throttle cable not used on GF4A EL 3 3 2 Do not replace converter if oil pan is full of debris CALL 3 3 MASH HOTLINE 3 3 2 3 accumulator is internal and not serviceable CALL MASH 7 3 HOTLINE 3 3 4 If cracked porous leakage damaged other CALL MASH 3 3 HOTLINE AAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU MAZDA AUTOMATIC TRANSMISSION APPLICATION TABLE 4 OF 6 3 External Components 7 NA4A HL LA4A EL 3 AATD 7 4R44F 3 3 3 3 3 AR55E 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAA
329. AAAC 3 3 3 Disconnect 20 pin EC AT 3 Yes Go to next step 3 control unit connector 3 3 3 Is there continuity E 3 3 between 2H terminal of AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 EC AT control unit and 2G No Repair Wiring 3 x 3 terminal of engine control 3 3 3 unit 3 3 3 3 4 3 Connect a circuit tester 3 Yes Go to step 6 2 3 to terminals 2P and ground 3 3 3 as shown in Fig 8 7 3 3 3 3 Is output voltage of reduce 3 3 3 torque signal at EC AT gt 3 3 3 control unit OK 3 3 Acceptable Voltages 3 No 3 Go to next step 3 Below volt Shifting 3 3 3 Battery voltage engine 3 3 3 3 idling 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 5 3 Disconnect 20 pin EC AT 3 Yes Go to next step 3 7 3 control unit connector 3 3 Is there continuity 3 3 3 3 between 2P terminal of AA AAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 EC AT control unit and 10 No Repair Wiring 7 3 terminal of engine control 2 3 3 3 unit 3 3 3
330. AARAAAAAAAAN 3 3 No Replace solenoid valve 3 3 3 lockup control 3 5 3 Disconnect negative 3 Yes Replace EC AT control unit 3 3 battery cable for at least 3 3 3 20 seconds AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Connect battery cable and No Intermittent poor connection 3 3 recheck for service cod 3 3 Check for cause 3 3 Is service code displayed 3 3 U Fig WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 24 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM 15 EC AT CONTROL UNIT ar OUTPUT SOLENOID CONNECTOR SOLENOID VALVE LOCKUP CONTROL 94B55435 Service Code 65 Circuit Diagram AFTER REPAIR PROCEDURE 1 Fig 2 Cancel the memory of service codes by disconnecting the negative battery cable for at least 20 seconds Reconnect the battery cable Fig 16 Remove the SST SELF DIAGNOSIS CHECKER or DTS1000 if connected 16 94C55436 Disconnecting Battery C
331. AARAARARARARAARARAAAAAAAARARARARAAAAAAARARAAARAARARARARARARAAAAAA 3 2 3 Disconnect 16 pin EC AT 3 Yes Go to Step 4 3 control unit connector 3 3 3 3 3 Is resistance between 1M 3 terminal and ground OK 3 No Go to next step 2 3 Resistance 10 20 ohms 3 AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 Disconnect solenoid 3 Yes Check wiring and connectors 3 3 3 connector 1 from EC AT control unit to 3 3 3 Is resistance between 3 3 solenoid valve lockup 3 3 ground and terminal F of 3 3 If OK go to next step 3 3 solenoid valve lockup Tf not OK repair wiring I 3 OK 3 3 and or connector 3 Resistance 10 20 ohms AAAAAAAAAARAAAARAAAARAAAARAAAAAAAAN 3 3 3 No Replace solenoid valve 3 3 3 lockup 3 WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 20 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM 3 4 3 Connect a dwell meter to 3 Yes Go to next step 3 3 terminals 1M and ground 3 3 i 3 3 as shown
332. ACEMENT GUIDE CAT U NO 001 94 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM RX 7 94152489 Fig 4 RX 7 Air Conditioning System Diagram A C O RING REPLACEMENT GUIDE CAT U NO 001 94 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM MPV x v 3 177 94652400 D Fig 5 MPV Air Conditioning System Diagram A C O RING REPLACEMENT GUIDE CAT U NO 001 94 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM 4 MN Ron 11 i ex 94D52491 Fig 6 626 MX 6 Air Conditioning System Diagram A C O RING REPLACEMENT GUIDE CAT U NO 001 94 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM MIATA 94E52492 Fig 7 Miata Air Conditioning System Diagram A C O RING REPLACEMENT GUIDE CAT U NO 001 94 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM NAVAJO 94 B TRUCK K Quantity 1 for low side J Quantity 1 for high side id 94F32493 H Qua
333. ADIAN CAT RC NO 95 01 Article Text p 33 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM S RY P RY a Ful Fuel 0 Pe Hose e Med of a o Fuel pipe main Cm step 32 2 S WD NS Y A SD S ZS X lt d SA i Orange White a J ci D 6 amp NOD e out w In 94559328 Fig 46 Exploded View of Tubes amp Hoses for Modification 6 Replace the front throttle body water hose with a new one and attach it with two new hose clamps See Fig 47 NOTE Holder must be removed from clamps Water hose N3A1 13 692A Clamps 99287 1400P x 2 pcs x w Install throttle body hose using two 2 new clamps 94A59345 Fig 47 Installing Throttle Body Hose N3A1 13 692A Use Two New Clamps RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 34 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 7 Use long needle nose pliers to remove hose clamps and replace the rear throttle body water hose with a new one Remov holders from clamps Attach with two new clamps See Fig 48 Water hose N3A1 13 681A Clamps 99287 1400P x 2 pcs Install New Rear Throttle Body Water Hose Use New Clamps DO NOT DAMAGE 94B
334. AIGN 60504 CANADIAN Article Text p 40 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 30 Replace the two vacuum tubes with new ones S Figs 58 Vacuum tube 99351 04150 x 2 pcs 94A59337 Fig 58 Location of Vacuum Tubes 31 Install the primary fuel distributor and the secondary fuel distributor to th ngine S Fig 59 NOTE Replace the four insulators with new ones Insulator for primary N3A1 13 257 x 2 pcs Insulator for secondary NFO1 13 257A x 2 pcs 32 1 Apply adhesive to the hose end on the primary fuel distributor outlet side indicated by the arrow in Fig 59 To apply adhesive s step 27 1 13 257A N3A1 13 257 f 94B59338 Fig 59 Installing Primary amp Secondary Fuel Distributors to Engine 32 2 Connect the hose between the fuel distributor and the vacuum RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 41 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM pipe assembly See Fig 60 NOTE Replace the clips outlet side of the secondary fuel distributor with new ones Clip Secondary 8574 13 157 For the direction of the clip claw see Fig 60 Do not
335. AK WIRE LENGTH INCREASED CAT G NO 001 93 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 19PM Damage Code 99 Part No of Main Cause FDY1 67 SHO Operation No XX0568RX Labor Hours 0 4 Hrs END OF ARTICLE AIR CONDITION MALFUNCTION HAZARD SWITCH CONTACTS CAT U NO 95 09 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 20PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN AIR CONDITIONING MALFUNCTION Model 5 1993 95 Mazda RX 7 Canadian Category U Heater amp Air Conditioning Bulletin No 95 09 Date August 1995 APPLICABLE MODELS VINS All 1993 95 RX 7 vehicles with a VIN of JM1FD333 80400026 and lower DESCRIPTION Either of the following conditions may occur when the air conditioning system is operated No compressor engagement when A C is switched on Air flow mode switch fixed in defrost position m Ihese conditions may be caused by insufficient contact at the hazard switch connector 1994 95 G 06 1993 G 01 See Fig 1 NOTE The hazard switch harness also contains the A C control connector m This improper connection does not affect the hazard switch operation Changes in the production process have eliminated this problem Customers complaining of the above sy
336. AL FALLOUT REPAIR PROCEDURE Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0797 07 Date July 1997 DESCRIPTION With the warm summer days ahead customers will be washing their vehicles more often and paint concerns such as those caused by environmental fallout acid rain rail dust water spotting etc can be more easily seen As a reminder when addressing these concerns please refer to the Mazda Paint Damage Repair Manual P N 9999 95 044N 94 This manual lists the recommended repair procedure and products supplied by Finish Kare Inc for proper removal of environmental fallout damage For questions or product information please contact Finish Kare Inc at 1 888 FINKARE 7 00 A M 3 30 P M PST Two copies of the Paint Damage Repair Manual will be mailed to your service department in the next publications mailing END OF ARTICLE GLOVE BOX LAMP STAYS ON NEW LAMP COVER CAT S NO 042 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 37AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN GLOVE BOX LAMP STAYS ON Model 5 1993 Mazda RX 7 with a VIN of JMIFD332 P0200001 through JM1FD332 P0210624 NOTE The asterisk in the VIN range can be any number 0 through 9 or X Category S Body Bulletin No 042 93 Date 10 21 93 DESCRIPTION
337. ANT LEAK 54407 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RECALL CAMPAIGN 54407 COOLANT LEAK Model 5 1993 94 Mazda RX 7 Category Recall Campaign Bulletin No 54407 Date August 8 1994 DESCRIPTION Dear Mazda Dealer Mazda Motor Corporation has decided to conduct Recall Campaign 54407 for replacement of selected engine cooling system components on certain 1993 94 Mazda RX 7 models beginning August 8 1994 We have determined that if an RX 7 has been subjected to high speed operation and then parked before cooling down the residual engine heat combined with the build up of pressure in the cooling system can raise the temperature of the coolant to levels where the integrity of the cooling system can be compromised Repeated operation of the vehicle in this manner may produce cooling system leaks Under some circumstances the leaking coolant mixture can collect on the top of th ngine where some of the water can evaporate increasing the concentration of the coolant If coolant then leaks onto the exhaust manifold an engine compartment fire could be the result The RX 7 is equipped with a water level sensor that warns the driver of low coolant levels with both a warning light and accompanying buzzer In most cases the driver would be
338. ARAAAAAAAAAAAAAAAAAAAAA AAA AAA AAA AAR AAA AAA AAAAAAAAAAAAAAAAAAAAAAAA 3 4 3 Connect a circuit tester 3 Yes Go to next step 3 3 to terminals 2D and ground 2 7 3 as shown in Fig 9 i 2 3 3 Is output voltage of 3 3 3 3 atmospheric pressure sensor 3 3 3 at engine control unit OK AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA Acceptable Voltages 3 Replac ngine control unit 3 2 0 4 5 volts ignition 3 2 3 3 3 switch ON 3 3 3 0 volts ignition switch 3 3 3 3 OFF 3 3 3 AAAAAAAARAAAAAAAAABAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 5 3 Disconnect negative 3 Yes Replace EC AT control unit 3 3 3 battery cable for at least 3 1 3 20 seconds AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 3 Connect battery cable and No Intermittent poor connection 3 recheck for service cod 3 3 Check for cause 3 3 Is service code displayed I AAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU ATMOSPHERIC CONTROL UNIT 94F55447 Fig 9 Service Code 58 Circuit Diagram SERVICE CODE 60 DIAGNOSTIC TABLE AAAAAARARAARARAARARAAAAAAAARAARARAAAAAAAAARAAAAAAAAAARAAAARARAARAAAA 3 Service Code No 60 3 Solenoid valve Shift A ARAAAAAARAAAAAAARAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998
339. ARARAAAAAAARA Diagnostics AARARARAARARARAARA RARAAAARARAAAARA U 3 MMA 3 UAAAAAAAAAAAAAAAAY 3 Results AA No Trouble A Contact Region AAA Found 3 Hot Line 3 3 AAAAAAKAAAAAAAAAAU gt Trouble Found d 3 3 3 3 AAAAAAAAAAAAAAAA 3 Complete 3 Hot Line 3 Check Sheet Instruction 3 3 Orden papt 5 Authorized AAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAU Replacement 3 Auth No Required UAAAAAAAAAAAAAAAAAAA Review Receive Parts 3 Diagnostics AAAAAAAAAAAAAAAAAAAAU 3 UAAAAAAAAAAAAAAAAAAAY Attach Copy Of 3 Check Sheet To 3 R O 3 A AAAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAAAAARA 3 Warranty Claim 3 Application SECTION 2 AIR FLOW METER DIAGNOSTIC PROCEDURES NOTE Procedures listed below do not apply to the following model year vehicles 1988 92 B2600 1989 90 RX 7 up to and including vehicles with a VIN of JMIFC3 L0806489 1993 RX 7 ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM 1 Check the air
340. ARD VERSION 2 01 TABLE for the application of this revised card PRICING The price of this tool is 235 75 SHIPPING AND BILLING INFORMATION This tool will be shipped prepaid via UPS to your dealer during the week of October 23 1995 Your parts account will be billed for this tool upon its receipt Please advise your shipping receiving personnel of this tool shipment NOTE This program card is small Therefore we recommend that your service manager shop foreman or lead technician install this card in the NGS tester and discard the discontinued card immediately This will prevent misapplication or misdiagnosis when using the NGS tester to service a Mazda vehicle OCTOBER 1995 SPECIAL TOOLS SHIPMENT CAT ST NO 007 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 40PM Ship Date Week of 10 23 95 95F51933 NGS Program Card Version 2 01 Fig 1 NEW APPLICATIONS FOR NGS PROGRAM CARD VERSION 2 01 NEW APPLICATIONS FOR NGS PROGRAM CARD VERSION 2 01 TABLE 3 NEW 3 APPLICABLE MODEL 3 PCM 1 3 TCM 2 ABS A C CCM 3 3
341. ATION PROCEDURES Labels are not self adhering and must be attached using tape the tape to the back side of the label and attach so that the the label faces the window PARTS INFORMATION TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA gt Part Number 7 Description 7 3 BR70 61 438 3 Label 3 U END OF ARTICLE B Series and Navajo Position label in the bottom comer of the drivers window Apply front of RECEIVER DRIER REPLACEMENT CRITERIA CANADIAN CAT U NO 95 02 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 08AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RECEIVER DRIVER REPLACEMENT CRITERIA WHEN REPLACING OTHER A C COMPONENTS Model 5 All Mazda Models with A C Canadian Category U Heater and Air Conditioner Bulletin No 95 02 Date March 1995 APPLICABLE MODELS VINS All models equipped with R12 and R134a Except 1994 and later B Series vehicles DESCRIPTION The following information is designed to assist dealers in determining the necessity to replace the receiver drier when replacing other A C components Do not replace the receiver drier unless the followin
342. ATURE SENSOR IGNITION Age SWITCH DATA LINK A RANA MODULE CONNECTOR TFA TERMINAL CHECK CONNECTOR ENGINE COOLANT TEMPERATURE SWITCH 98E51627 Fig 14 Cooling Fan Control System Components SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 18 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM Operation Engine condition A C op Cooling fan No electrical load RC Mm No 1 Engine coolant temperature below 105 C 221 F Cooling fan a No 2 Cooling fan Cooling fan E m No 3 s No ane Engine coolant temperature 105 108 C 221 226 F In 10 min after ignition Engine cool switch is tumed OFF ant tempera Engine coolant tempera ture over 108 ture above 108 C 226 C 226 F F for more than 2 min after ignition before ignition switch is switch is turned OFF Engine cool ant tempera ture becomes lower than 108 C 226 F after igni tion switch is tumed OFF tumed OFF ete E EE EE ME MN NL Engi above 108 C ee NE RS TEE ero on T e se Engine coolant temperature sensor mal function TFA terminal ground 98H51745 Fig 15 Cooling Fan Control System Operation SYSTEM INSPECTION 1 Verify that the engine coolan
343. Advisers and Service Managers should review the criteria below for addressing customer complaints regarding cracked windshields If possible customers should be present when the inspection is performed INSPECTION PROCEDURE 1 Visually inspect the length of the crack and the windshield molding for signs of stone contact 2 Trace the length of the crack with a needle or small nail to determine chipping location IMPORTANT Windshield replacement is not warrantable if a chip larger than 1 mm in diameter exists along the length of the crack Inspect All Along Windshield Molding Trace A Needle Or Nail Along Crack To Determine Chip Location Windshield Replacement Is Unwarrantable If The Chip Diameter Exceeds 1mm 95C55386 Fig 1 Windshield Inspection WINDSHIELD STONE CHIPPING INSPECTION CAT S NO 037 96 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 45AM END OF ARTICLE ABS LIGHT ON MODELS WITH 4 WHEEL ABS MT 0997 04 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 23AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER DEALER HINT ABS LIGHT ON Model s 991 97 Mazda 626 MX6 Miata 991 95 Mazda 929 RX7 1992 95 Mazda MX3 1994 Mazda Navajo 1995 97 Ma
344. Apply battery positive voltage and ground to terminals A and B of the cooling fan relay See Fig 11 3 Check continuity of the relay TERMINAL CONTINUITY TABLE Operation 3 A Type Terminals D E 3 3 B Type Terminals C D B applied 3 Continuity 2 3 B not applied 3 No continuity U 3 NOTE B Battery positive voltage 4 If not as specified replace the cooling fan relay For additional wiring schematic information see Figs 16 and 17 5 NE o dcr x S gt a aNE os Fssfe 5 o frees lt 5 S PSs Copyright 1998 Mitchell Repair Information Company LLC SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 t Z 589 D9SIABM Lj D H3 wn 43 BATYA BATA ONTHOLIAS 43 DAIWA SSYd18 3 JAWA 3A1YA OION310S OTON3108 JAWA 010N3105 O10N370S 893 62 18 YY AuYvQNO235 02 19 WIY A vON0J16 L2 18 O
345. B01 67 099 M T Non Turbo A T 1990 92 929 9295 Engine Compartment FB01 67 099 1986 92 323 Engine Compartment FB01 67 099 1987 89 323 Wagon Engine Compartment FB01 67 099 1986 91 93 RX 7 Engine Compartment FB01 67 099 FUSIBLE LINK REFERENCE CHART NO T 2 3 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 34PM 1992 MX 3 Engine Compartment FB01 67 099 1984 86 GLC Wagon Engine Compartment 8573 66 760 END OF ARTICLE HESITATION WHILE DRIVING CHECK ENGINE GROUND STRAP CAT F NO 005 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 35PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN HESITATION JERKING BUCKING WHILE DRIVING Model 5 1993 95 Mazda RX 7 Category F Fuel amp Emission Control System Bulletin No 005 97 Date March 10 1997 DESCRIPTION A jerk or bucking condition may occur under any of the following conditions Under light to moderate acceleration Cruising at engine speed of 2000 2200 rpm A C ON This concern may be caused by improperly grounded engine harness creating high resistance in the engin
346. BULLETIN TURBOCHARGER Model 5 1993 95 Mazda RX 7 Category Mazda Tips Bulletin No MT 0495 07 Date April 1995 SERVICE INFORMATION During engine replacement or other engine disassembly cracks on the turbocharger exhaust manifold may be present Due to the high heat concentration existing in the turbocharger and manifold some cracks in the shaded areas are considered normal and the turbo does not need to be replaced NOTE Cracks will not extend in length because the outer wall temperature is comparatively low The following are acceptable conditions and the turbo does not need to be replaced 1 Cracks of 5mm or less in length that do not pierce the housing EXCEPT 2 At the top of the secondary turbo flange next to the turbo pre control valve cracks of 13mm or less are acceptable See Fig 1 94099917 Fig 1 Location Of Cracks On The Turbocharger END OF ARTICLE INTAKE MANIFOLD GASKET PRECAUTIONS CAT F NO 005 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 34AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN INTAKE MANIFOLD GASKET PRECAUTIONS Model 1986 94 Mazda RX 7 Category F Bulletin No 005 95 Date 3 15 95 Date Revised 6 16 95 APPLICABLE MODEL VIN 1986 94 RX 7 Model Vehicles DESCRIPTION Rough idle that occ
347. CATIONS CANADIAN CAT N NO 95 02 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 22AM ITAN 3 indicated is E not mentioned 3 3 R 3 3 also described No specification 3 A A AA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Thrust Angle 3 0 8 degrees d 3 3 NOTE Each vehicle varies in specification median Refer to the x 3 Workshop Manual for each vehicle s specification 3 U VEHICLE PREPARATION AND CONDITION 1 The vehicle should have No Passengers No Luggage Gas Tank Full Radiator And Engine Oil To The Specified Levels Spare Tire Jack And Tools Stored In Designated Areas Tire Pressure Checked And If Necessary Adjusted HF NOTE If the specifications are different depending on load conditions adjust the pressure for the lightest load 2 The table below contains examples of front caster specifications based on fuel tank level CASTER SPECIFICATION TABLE
348. CHNICAL SERVICE BULLETIN DIAGNOSTIC PROCEDURES FOR ECU S AIR FLOW METERS FUEL PUMPS AND ALTERNATORS Model 5 Category Category 1988 94 Mazda Vehicles G Engine Electrical G Engine E except Navajo and 1994 B Series No 002 93 Date 9 16 93 Now 93 03 Date Oct 93 ilectrical DESCRIPTION This bulletin contains diagnostic and repair procedures for the following components Engine Control Units ECU Air Flow Meters Fuel Pumps Alternators Each procedure includes the following 1 Outline Of Diagnostics Parts Requirements And Warranty Application Illustrates the steps from diagnostics through parts return and warranty submission 2 Diagnostic Procedures Step by step testing of the component and circuit 3 Component Check Sheet Details of the customer complaint and events leading to the repair NOTE Proper completion of the check sheets are required for warranty claim submission INDEX SECTION 1 Outline ECU Diagnostics ECU Check Sheet SECTION 2 Outline Air Flow Meter Diagnostics Air F SECTION 3 Low Meter Check Sheet ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Outl Fuel Fuel SECTION 4 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM ine Pump Diagnostics Pump Check Sheet Outline
349. CLE BEGINNING TECHNICAL SERVICE BULLETIN BLACK FINISH PEELING FROM INTERIOR TRIM Model s 1993 Mazda RX 7 with a VIN ofJM1FD331 P0207441 or lower produced through August 4 1992 Category S Body Bulletin No 056 93 Date 12 15 93 DESCRIPTION Some vehicles may experience the black finish peeling from certain interior trim parts Fig 1 illustrates the affected parts e a Arm Rest Trim Lid L Front Assist Center Panel Grip R 94H53188 Switch Panel Fig 1 Affected Parts This condition is caused by poor adhesion of the black finish to the trim parts REPAIR PROCEDURE The adhesiv lement has been strengthened to prevent the interior trim black finish from peeling If peeling occurs replace the affected parts See PARTS INFORMATION TABLE for list of modified parts Refer to the appropriate service information for removal and installation procedures BLACK FINISH PEELING FROM INERIOR TRIM REPLACE PART CAT S NO 056 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 34AM PARTS INFORMATION TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAR 3 Part Number 3 Description 3 Quantity 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 55 210B 00 3 Central Panel 3 3 Ah AAARRAAAARAAAAAAAAARAAAARAAAARAAAAAAAAAA
350. CODES CAT W NO 034 92 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM EC AT CONTROL UNIT PULSE GENERATOR 94B55427 6 Service Code 55 Circuit Diagram CE CODE 56 DIAGNOSTIC TABLE 3 Service Code 56 ATF Thermosensor 3 Step Inspection Action 3 AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1 3 Are there any poor 3 Yes Repair or Replace connector 3 connections at ATF 3 3 3 3 3 thermosensor and EC AT AA AAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 control unit connector or iNo Go to next step 3 3 terminal 3 AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 2 3 Connect a circuit tester 3 Yes Go to Step 5 3 3 to terminals 2R 2L as 7 E 3 3 3 shown in Fig 7 3 3 3 3 Is input voltage of ATF 5 3 3 3 3 thermosensor at EC AT AA AAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 control unit OK 3 No 3 Go to next step 3 3 3 Acceptable Voltages
351. D01 66 4 0 Quantity 1 Operation Number TO204XRX Labor Hours 0 3Hrs END OF ARTICLE ANNOUNCEMENT OS SST UPDATE PROGRAM 001 CAT ST NO 001 94 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 21PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ANNOUNCEMENT OF SST UPDATE PROGRAM Model 5 1993 94 Mazda RX 7 1995 Mazda Millenia Group ST Bulletin No 001 94 Date 6 22 94 DESCRIPTION The Special Service Tool SST involved in this program is the RX 7 harness adapter 49F0 18 902 It was a Minimum Required Tool MRT This harness adapter has been discontinued by Mazda s tool vendor America Kowa Seiki Inc and has been replaced by a new harness adapter 49T0 18 902 which is applicable to both the RX 7 and the new 1995 Millenia This new tool is now a MRT The cost of this new harness is adapter is 457 71 The visible difference between the two harness adapters is that the new harness adapter has an added power source a cigarette plug adapter Additional Power Source Cigarette Plug Adapter NEW 49 FO 18 902 Harness Adapter NEW 49TO 18 902 Harness Adapter 94852481 49 018 902 CONNECTOR 8 Fig 1 New 4950 18 902 amp 49TO 18 902 Harness Adapter PARTS INFORMATION TABLE AARAARARAARAAAAAAAARARAAAARAAAARAAAARARAAAAAAAAAAAAAAAAAARARAAAAAA 3 Description A Part Number
352. DX T 3 and 3 Per s 3 Code 3 3 Kit Numbers 3 Vehicle 3 3 8mm 6 936 1 o8 LB51 61 J1X 3 4 3 3 D 3 12mm 10 8 x 1 78 3 LB54 61 J1X 1 3 3 E 3 12mm 10 8 x 2 4 LB55 61 J1X 3 1 3 3 3 axial 3 3 3 3 3 F 3 16mm 14 0x 1 78 3 LB56 61 J1X 7 2 3 3 G 3 16mm 3 l3 4 224 3 LB57 61 J1X 1 3 3 3 3 3 3 axial 3 AAAAAA RAAAAAAAA AAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAARAU NOTE Part numbers ending in J1X are delivered in quantities of 10 Se
353. Date November 7 1996 NOTE This bulletin replaces bulletin Cat N No 001 94 and Cat N No 005 95 APPLIED MODELS VINS All Models except the Navajo and B Series DESCRIPTION Some vehicles may have an off center steering wheel but no right or left hand pulling Customers complaining of this concern should have the vehicle inspected and if necessary repaired according to this bulletin REPAIR PROCEDURE 1 Test drive the vehicle on a straight road 2 Place the steering wheel in a neutral position If the vehicle tracks straight and the steering wheel is NOT in a centered position proceed to step 3 3 Use the outside circumference of the steering wheel to measure the distance between the center position and the neutral position If the measurement is more than 30mm 1 18in remove the steering wheel and install it in the centered position See the workshop manual for removal and installation procedures Tf the measurement is less than 30mm 1 18in a Loosen both right and left hand tie rod end lock nuts STEERING WHEEL SLIGHTLY OFF CENTER CAT N NO 001 96 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 24AM b Turn the tie rod ends in opposite directions by equal amounts until the steering wheel is centered 3 Verify the repair The chart below shows the a
354. Division 62050 U S Environmental Protection Agency 401 M Street S W HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Washington D C 20406 APPROVED REFRIGERANT RECOVERY RECYCLE EQUIPMENT The following lists contain the section 609 approved refrigerant recover recycle and recover only equipment TABLE Contains recover recycl quipment approved by Underwriters Laboratory UL and ETL Testing Laboratories Inc TABLE 2 Contains recover recycl quipment determined to be substantially identical to approved equipment TABLE 3 Contains recover only equipment approved by Underwriters Laboratory UL and ETL Testing Laboratories Inc TABLE 4 Contains recover only equipment determined to be substantially identical to approved equipment A l lists will be updated as equi
355. E END OF ARTICLE NOISE WHEN TURNING STEERING WHEEL NEW RACK BOOTS CAT N NO 002 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 24AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN NOISE FROM FRONT OF VEHICLE WHILE TURNING STEERING WHEEL Model 5 1993 Mazda RX 7 with a VIN of JM1FD33 P0200001 through JM1FD33 P0210661 NOTE The asterisk in the VIN range can be any number 0 through 9 or X Category N Steering Bulletin No 002 93 Date 10 21 93 DESCRIPTION Turning the steering wheel while the vehicle is stationary may produce an unusual noise from the front of the vehicle This noise is generated from the steering linkage boots The diameter of the boots have been increased to correct this problem REPAIR PROCEDURE 1 Confirm the noise If the noise is coming from another source refer to the appropriate service information for troubleshooting information lf the noise is coming from the boots proceed to step 23 2 Replace the boots with the redesigned boot DIL OLD 94653047 Fig 1 Steering Gear Dust Boots PARTS INFORMATION TABLE
356. E and flow charts below depending on the test equipment The final voltage must be above the minimum value shown in the table Record the voltage on the Battery Check Sheet If the voltage is more than the minimum measure the open circuit voltage Charge the battery if less than 12 4V If the voltage is less than the minimum quick or boost charge the battery for 30 minutes CAUTION DO NOT Quick or Boost charge MX 5 Miata batteries Thes batteries are gel type and must NOT be charged at more than 20 amps Perform a load test again If the battery is still below the minimum voltage replace the battery and proceed to step 8 7 Start the vehicle and raise the RPM to 2500 8 Connect the battery load tester and apply a load equal to the alternator rating If the voltage is 13 5V to 15 0V the alternator and battery are MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 unct th f th Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM ioning correctly e voltage is more than 15 0V replace the alternator e voltage is 13 5V or under check for resistance between the battery and terminals B and S Inspect the harness for damage Repair as necessary Retest the alternator If the voltage is s
357. EAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 28 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM _ Pressure Sensor 25 te NZS TA EIR A Nez ay ACV Vacuum Hose EGR Vacuum Hose 94159319 Fig 37 EGR Vacuum Hose amp ACV Vacuum Hose Fig 38 Hoses to Disconnect 94059321 lt Th x B Fig 39 Switch to Disconnect 17 Remove th xtension manifold and throttle body RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 29 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM NOTE Cover exposed intake holes with shop towel Torque for re tightening the bolt Tightening Torque 160 230 kgf cm 139 199 in lbf When reassembling replace the intake manifold gasket with a new one Gasket N3A1 13 112 18 Remove the following parts See Figs 40 amp 41 WW 94D59322 Z f Y E Fig 40 O2 Sensor Coupler on the ACV DO NOT DAMAGE Fig 41 ACV Vacuum Tubes 19 Remove the nut shown in Fig 42 Remove the thr way solenoid RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 30 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Informat
358. ER DEALER HINT ETR OPERATION Model 5 All Mazda Models Category Mazda Tip Bulletin No 0297 05 Date February 1997 DESCRIPTION Bob White of the Southeast Region worked with Ferman Mazda In Tampa Florida on an ETR audio unit concern The customer complaint was that the auto reverse cassette player switched directions intermittently when it wasn t at the end of the tape After trying to duplicate the concern with different tapes they found it was specific just to some cassette tapes Certain tapes had too much internal resistance and caused the ETR to sense end of tape and reverse TH a customer complains that the auto reverse function of the ETR operates incorrectly see if it occurs only on certain tapes Then manually check the movement of the tape with a pencil to see if it rolls easily compared to other tapes If the resistance is Significantly higher the tape is most likely the cause of the concern not the ETR END OF ARTICLE FRONT WIPER MOTOR INOPERATIVE MT 0394 15 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 31PM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER FRONT WIPER MOTOR INOPERATIVE RENEWABLE CIRCUIT BREAKER Model s 1986 94 Mazda Models Category Mazda Tips Bulletin No MT 0394 15 Date March 1994 DESCRIPTION If the fron
359. ERING AND WARRANTY APPLICATION DEALER Diagnostics MMA 3 UAAAAAAARAAAAA gt 7 Results AA No Trouble A Contact Region AAA AA AU Found Hot Line 3 AAAAAAAAAAAAAAAAAU 7 Trouble Found 2 3 3 3 AAAAAAAAAAAAAAA 7 3 Complete 3 3 Hot Line ue 3 Check Sheet AAAAAAAAAAAAAAA Instruction 3 3 3 Order Part Authorized AAAAAAAAAAAAAAAAAU 3 Replacement 3 3 3 Auth No Required AAAAAAAAAAAU Review 3 Receive Parts Diagnostics 3 3 Return Repl Part 3 3 With Check Sheet 3 3 To Your Servicing 3 3 PDC d 3 3 Warranty Claim 3 3 Application ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM SECTION 1 ECU DIAGNOSTICS PROCEDURE 1 Disconnect ECU connectors 2 Connec
360. FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 43 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM the ground terminal See Fig 62 3 Pinch the fuel return hose with a suitable tool to stop any fuel return to the tank See Fig 63 NOTE Use a dull edged SST so that it does not damage the hose Operate the fuel pump for more than five minutes and check for fuel leakage Check for fuel leakage visually and by odor Carefully check the positions seven indicated by the arrows in Fig 63 If fuel leakage is found repair the problem Once repaired check again according to the above steps Diagnostic Connector To Ground Terminal 94659341 Fig 62 Diagnostic Connector to Ground Terminal RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 44 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Pinch here to prevent fuel return 94H59342 Fig 63 Seven Fuel Leakage Areas 34 Install the vacuum pipe assembly Replace the vacuum tubes 4 5 6 7 10 and 11 with new ones 2 Connect the hoses 3 14 to the vacuum pipe assembly 3 Connect the coupler of each solenoid valve
361. Finding the Circuit Opening Relay 6 Disconnect the negative terminal from the battery RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 25 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM NOTE Record all preset stations on the vehicle s audio system prior to disconnecting the battery terminal 7 Drain coolant and retain in an appropriate container 8 Remove the bolts from the duty solenoid and the pressure chamber Tightening Torque 70 100 kgf cm 61 86 in lbf See Fig 33 Duty Solenoid Remove Bolts from Duty Solenoid 94E59315 Fig 33 Removal of Bolts from Duty Solenoid 9 Disconnect the air pipe at joint A shown in Fig 33 10 Disconnect the AWS hose and the air duct B at the joint as shown in Figs 34 Cover Outlet With Shop Towel 94F59316 Fig 34 Disconnecting the Air Pipe amp Hose 11 Remove the air intake pipe from the outlet of the turbo and cover RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 26 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM the outlet with a shop towel 12 Remove the air duct from the inter cooler 13 Remove the hoses from the extension manifold
362. G Do not smoke carry lighted tobacco or an open flame of any type when working on or near a fuel related component Highly flammable mixtures are present and may be ignited resulting in possible injury 1 Connect the negative terminal to the bakery 2 Connect the fuel pump terminal of the diagnostic connector to RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 43 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM the ground terminal See Fig 62 3 Pinch the fuel return hose with a suitable tool to stop any fuel return to the tank See Fig 63 NOTE Use a dull edged SST so that it does not damage the hose 4 Operate the fuel pump for more than five minutes and check for fuel leakage Check for fuel leakage visually and by odor Carefully check the positions seven indicated by the arrows in Fig 63 If fuel leakage is found repair the problem Once repaired check again according to the above steps Diagnostic Connector To Loans Terminal 94G59341 Fig 62 Diagnostic Connector to Ground Terminal RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 44 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM Pinch her
363. GN 60504 CANADIAN CAT RC NO 95 01 Article Text p 22 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Pinch here to prevent fuel return ep 94H59342 Fig 29 Seven Fuel Leakage Areas 34 Install the vacuum pipe assembly See Fig 30 Replace the vacuum tubes 4 5 6 7 10 and 11 with new ones 2 Connect the hoses 3 14 to the vacuum pipe assembly 3 Connect the coupler of each solenoid valve 4 Install the vacuum pipes to the engine by tightening the bolts three pieces Tightening Torque 160 230 kgf cm 139 199 in 1bf Vacuum tubes 10 and 11 N3A4 20 344 x 2 pcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 23 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 0000 9 CO y SI Y Orange NS 94159343 Fig 30 Installation of Vacuum Tubes 35 Assemble the pans in the reverse order of removal 36 Affix the recall label No 60504 onto the driver s side door for future confirmation that the campaign has been completed on this vehicle 8 Fig 31 Recall Label 60504 94J59344 Fig 31 Recall Label 60504 Identification FUEL HOSES AND COOLING COOLANT SYSTEM REPLACEMENT
364. ING FLUID OUT FLUSHING FLUID IN d 97B57522 Fig 2 Back Flushing Flow AUTOMATIC TRANS COOLER LINE FLUSHING PROCEDURE CAT K NO 005 98 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM COOLER IN LINE FLUSHING FLUID OUT COOLER OUT LINE 97C57523 Fig 3 Forward Flushing Flow AUTOMATIC TRANS COOLER LINE FLUSHING PROCEDURE CAT K NO 005 98 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM FRONT WHEEL DRIVE TRANSAXLE REAR WHEEL DRIVE SIDE VIEW SIDE VIEW MPV RX 7 929 MIATA NA PROTEGE MILLENIA KL 626 FS SIDE VIEW B TRUCKS MILLENIA KJ SIDE VIEW MIATA NB 97D57524 Fig 4 A T Transaxle Fluid Flow amp Cooler Line Fitting Locations WARRANTY INFORMATION NOTE This information applies to verified customer complaints on vehicles covered under normal warranty Refer to the SRT microfiche for warranty term information When you submit a warranty claim on automatic transmission complete replacement add any of the following operation numbers and labor hours to the operation number and labor hours for automatic transmission complete R amp R
365. IONI30S 284 92 18 SSYdAB 1804 2 18 331138 2 18 55 416 IY LITdS C2 8 HOSNISDHHIHI 7304 22 18 e l 125 43 R3 W3 84 HOSN3S 8 38 AUYQNO23S CINOU3 AYYONOI3S 8738 iuvHIBd CLNOUA AUVHIUd 8 1Y3H 61 18 40123CNI 81 16 80133CNI 1 t8 WO123CNI 91 18 WOI23CNI 1 18 ED a ast 3 UOSN35 3unss3Hd ONIU331S 12 19 AARAA o al fs Tree vor Ye Ov 9 Sy Nr Pv TS T t oY 3 83 13815831 31n004 JOHNI HIVHIH3AOd 10 18 31 b C 99 NO11235 1 3 13351 31 2 N0I123S z ng c ON1N0J NIVHLM3A0d 1238 N211AS NYA HOLIAS 316N79 1 H NOTI23S 84 8 L ON Ad LINN H31Y3H NOILYKIBKOD 1N3HAELSNI NOISSIXSNYBL and 2 6 NO11235 INOOH EY 111 8 491 2 NOLL23 b ON 2 0N a 62 62 1081502 VA 61 18 H316012 SiY13N 4 8 NI 3 04 38 48 1N3HDHI SNT 1NY 1003 1 36 91 2 8011235 uy QUVZVH 22 19 6 62 uismo 4 LY3H Di YOSN3S HOSNIS LN3HAYLSNE eiie astris Eee Med eo SNINEVA 3 4 9 83315 83 1V3H zi 1z fe a A 14 213 AIT wo W jus yas ira Gu 243 4788 4 3 04 3 n sz x 3471 L x yo YA vo 7 0 1i1 41 0 ex 4 31 L 011236 qup MOTA 1 mie Guy aa D AY138 NIYM 153 3819831370004 QUINOJ 8 83 04 DEL wad ui 3 as wal 431 Pru ED wa wa Wal Ya 90 1 0 5 3 8 A 8 5 479 81
366. Information Company LLC Saturday August 25 2001 10 18AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN REMANUFACTURED TRANSMISSIONS Model 5 All Mazda Canadian Models through 1995 Category J Manual Transmission Bulletin No 95 02 Date May 1995 DESCRIPTION Remanufactured Transmissions and Transaxles which are supplied by Mazda Canada Inc are rebuilt by M A N A Mazda North America Inc This division of Mazda supplies remanufactured units for both Canada and United States In their continued efforts to upgrade the quality of these remanufactured units they are looking for more information on what initially failed and why This will allow the cause to be recognized and addressed during the remanufacturing of the failed unit To assist M A N A in their efforts the following procedures will be put into place immediately 1 A properly completed Warranty Tag P N 9999 94 5011 E F must be attached directly to the body of the core unit Attachment 41 is a completed sample 2 A properly completed Automatic Transmission Diagnosis Information Sheet must be folded twice and stapled to the Warranty Tag See Fig 1 Fig slags REMANUFACTURED TRANS CANADIAN DIAGNOSIS SHEET CAT J NO 95 02 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 18AM
367. Iroubleshooting Manual for troubleshooting and repair information The following are additional Midtronics Power Sensor Plus tester features Position A Will test for an open circuit bad cell or broken internal circuit This is indicated by a Red LED light If an open circuit is indicated replace th battery using the criteria described in the warranty section of this bulletin Position B A green LED indicates that the battery has at least 10 2V and can therefore be tested without pre charging This position requires that the CCA rating for the specific battery type under test be MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM set on the Midtronics Power Sensor Plus Tester dial Refer to the WET BATTERY APPLICATION GUIDE to determine CCA The Midtronics Power Sensor Plus tester then determines actual CCA by measuring the condition of the battery voltage and plate condition Position C Measures the alternator output when th ngine is running and also indicates Open Circuit Voltage Position D Indicates actual CCA condition of the battery By comparing the indicated reading to the battery s rated CCA the battery condition is determined ex Indicated CCA of 400 for a ba
368. L CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 18 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 30 Replace the two vacuum tubes with new ones S Eig 24 Vacuum tube 99351 04150 x 2 pos 242 al EH 7 S 4 94A59337 an Fig 24 Location of Vacuum Tubes 31 Install the primary fuel distributor and the secondary fuel distributor to th ngine S Fig 25 NOTE Replace the four insulators with new ones Insulator for primary N3A1 13 257 x 2 pcs Insulator for secondary NFO1 13 257A x 2 pcs 32 1 Apply adhesive to the hose end on the primary fuel distributor outlet side indicated by the arrow in Fig 25 To apply adhesive s step 27 1 N3A1 13 257 x 94B59338 Fig 25 Installing Fuel Distributors to the Engine 32 2 Connect the hose between the fuel distributor and the vacuum RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 19 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM pipe assembly See Fig 26 NOTE Replace the clips outlet side of the secondary fuel distributor with new ones Clip Secondary 8574 13 157 Clip with Pink colored holder
369. LB54 61 J1X 2 3 3 3 L mm 3 14 0x 1 78 3 LB56 6 4 3 E 1 1 U NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 17 for O Ring Identification B Series 1990 93 95C 51948 Fig 17 1990 93 B Series O Ring Identification D Bottom 1994 96 B SERIES O RING DESCRIPTION TABLE NO 3 Pipe O Ring 3 Part Numbers 3 Quantity 3 3 Ring 3 Size 3 Size DX T 3 and 3 Per s 3 Code 3 3 3 Kit Numbers 3 Vehicle 3 H Sein 5 Reso 3x 1 90 ZZLO 61 J19 KIT 3 3
370. LC Saturday August 25 2001 06 56AM NOTE Cover exposed intake holes with shop towel Torque for re tightening the bolt Tightening Torque 160 230 kgf cm 139 199 in lbf When reassembling replace the intake manifold gasket with a new one Gasket N3A1 13 112 18 Remove the following parts See Figs 40 amp 41 WW 94D59322 Z f Y E Fig 40 O2 Sensor Coupler on the ACV DO NOT DAMAGE Fig 41 ACV Vacuum Tubes 19 Remove the nut shown in Fig 42 Remove the thr way solenoid RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 30 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM NOTE Do not remove the vacuum tube from the solenoid Tightening Torque 70 100 kgf cm 61 86 in lbf 94F59324 Fig 42 Three Way Solenoid Nut to be Removed 20 Remove the oil filler pipe See Fig 43 Tightening Torque 70 100 kgf cm 61 86 in lbf 4 ww Y W 94G59325 Fig 43 Oil Filler Pipe Identification 21 Remove the ignition coil assembly Remove the four nuts shown in Fig 44 Tightening torque of the nuts for reassembly Tightening torque 70 100 kgf cm 61 86 in lbf RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 31 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitc
371. LE 1 AARARAAAARAARARARAARARAARARAAAAAAAARAAAAAAAAARAAAARAAAAAAAAAAAAAAAAA Claim Submission 3 Dealer Reimbursement 3 AAAAAAANAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAMAAAAAAAARAAAAAAARAAABARARAAAR 3 Warranty type K 3 Warranty labor 3 3 rate 50 00 hr 3 WARRANTY BULLETIN MAZDA BATTERY WARRANTY CAT G NO 1 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 47PM 3 Symptom code 20 3 3 3 Damage code 81 3 3 3 Vendor code KN999 3 3 3 Part number 3 3 3 main cause 0000 80 0065 WB 3 3 3 Quantity 1 3 3 Pro Rate 50 3 42 22 DNP 30 50 3 3 Related part s 0 wet battery acid 3 3 3 is not required 3 3 3 Labor operation no labor 3 E Labor Hours customer s dealer s 3 3 3 responsibility 3 3 3 Total 3 3 reimbursement 42 22 3 3 CUSTOMER S RESPONSIBILITY battery pro rate 3 A ny Nera AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU BATTERY VENDOR CODES TABLE 3 Vendor 3 Vendor Code ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Delco Freedom E KN160 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 GS 3 K4239 3
372. LOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM SECTION 1 ECU DIAGNOSTICS PROCEDURE 1 Disconnect ECU connectors 2 Connect SST Engine Signal Monitor And Adapter as shown in Fig 1 Place application panel sheet on the Engine Signal Monitor ECU Application Panel Sheet 94D53028 Engine Signal Monitor Fig 1 Engine Signal Monitor and ECU 3 Measure the voltage according to the specifications in the appropriate service information 4 If the voltage is different than specified check the related input and output devises and wiring for damage If no problem is found and the reading remains out of specification replace the ECU 5 If the voltage is within specification and the problem still exists contact the Technical Hotline for assistance CAUTION Terminals A amp B are for external voltmeter connections Use these terminal to attach a digital voltmeter or oscilloscope for precise volt readings See Fig 2 for illustration Never apply current to these terminals damage to the ECU will result ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday Aug
373. MISSION DIAGNOSTIC SHEET ATDS retained with the R O Using the WARRANTY REPAIR GUIDE determine if the concern can be corrected by performing allowable adjustments repairs or component part replacement listed on the guide Perform the adjustments repairs or compon nt replacements f the transmission or components are replaced ush the transmission cooler prior to installation If an internal part is suspected call the MASH hotline for assembly authorization Prepare the core for return shipment to MANA in the original shipping container This includes draining the fluid replacing the h completing and cm Perform a quality ole plugs and torque convertor retaining strap attaching the core tag and a copy of the ATDS check thorough road test and visual inspection made to ensure complete customer satisfaction after repairs ar Including the cus tomer in the road test is recommended AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW CHART 3 3 Listen To Customer Road Test Customer Complaint 3 AAU AAAAAAAAAAAAAA Complaint 3
374. Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM 3 Step Inspection 3 Action 3 AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1 3 Are there any poor Yes Repair or Replace connector 3 3 connections at solenoid 3 3 3 valve and EC AT control AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 unit connectors 3 No 3 Go to next step AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Connect a circuit tester 3 Yes Check wiring and go to 3 3 3 to terminals 1D and ground 3 Step 5 3 3 as shown in Fig 10 gt x 2 3 Is output voltage of 3 E 3 3 solenoid valve shift A A MAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 3 at EC AT control unit OK 2 Go to next step Acceptable Voltages Battery voltage lst or 3 H O D gear 3 3 w w www Below volt 2nd 3rd gear AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 Disconnect 16 pin EC AT 3 Yes Go to Step 5 3 3 control unit connector 3 3 3 3 Is resistance between 1D AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAA 3 3 terminal and ground OK 3 No Go to next step 2 3 3 Resistance 20 40 ohms 7 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 4 3 Disconnect solenoid 3 Yes Check wiring and connectors 3 3 connector 3 3 from EC AT control unit to 3 3 Is resistance between 3 3 solenoid valve sh
375. N Steering Bulletin No 001 95 Date 1 19 95 NOTE This bulletin was originally released as Cat N 4003 94 Replace the original bulletin with this revised copy APPLICABLE MODELS All models except Navajo and 1994 and on B Series DESCRIPTION und information on standard for wheel alignment This bulletin provides backgro Specification and measuring co nditions f te Variations occur the vehicle at the Measured values are not absolu equipment and the condition of between tec time of meas hnician urement To avoid unnecessary adjustments specifications and measurement conditions have been changed in the workshop manual These changes are described below NOTE Changes in the specifications do not imply that alignment tolerances have increased during production Vehicle alignment is set to the median specifications during production and technicians should also use median specifications during alignment adjustment NEW SPECIFICATIONS TABLE AAAAARARAARARAARARAAAARAAAAAAAAAAAAAAAAAARAAAARARAARARAAAAAAAAAAAAAA 3 Items 3 Standard Tolerance 3 Note AARARARAAAAARARAAAAAARARARARARARAAARAAAAARARAAAARARARARARAAAAARARARAR 3 Front Camber Difference 1 1 5 3 between right and 7 3 left 3 3 Caster Difference 1 1 5 3 between right and 3 w w www tQ www gt degrees 3 3 3 3 3 3
376. NTROL SYSTEM 1993 RX 7 DESCRIPTION To improve idle smoothness and engine reliability the cooling fan control system controls the electrical fan speed by ECM This system consists of the cooling fan cooling fan relays cooling fan control module ECM and input devices S Figs 3 and 4 ENGINE COOLANT TEMPERATURE COOLING FAN 1 AE sumi P DATA LINK cuc LEA MODULE CONNECTOR TFA TERMINAL LA CHECK CONNECTOR ENGINE COOLANT TEMPERATURE SWITCH 98E51619 Fig 3 Cooling Fan Control System Components Fig 4 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC 221 F Engine condition No electrical load Engine coolant temperature below 105 C Sunday August 19 2001 01 44PM switch ON In 10 min after ignition switch is tumed OFF Engine coolant tempera ture above 108 C 226 F for more than 2 min before ignition switch is turned OFF function 98E51742 Cooling Fan Control System Operation SYSTEM INSPECTION 1 2 Turn the ignition switc 3 Turn the ignition switc 4 Ground the check connect 5 Up to VIN JM1 FD331 verify that the cooling fa seconds after t 6 Verify that the engine coolant temperature is below 80660 Engine coolant temperature 105 108 C
377. NTY INFORMATION Applies to Vehicles Covered Under Warranty Warranty Type Code A Customer Comment Code 82 Damage Code 9A NOISE WHEN OPERATING POWER WINDOWS NEW STOPPER CAT S NO 031 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM Part No of Main Cause FDO1 58 565 Quantity 1 Operation No S1015XRX Labor Hours 0 7Hr END OF ARTICLE OUTER DOOR HANDLE RATTLES REPLACE NUTS CAT S NO 026 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN OUTER DOOR HANDLE RATTLES Model 5 1993 MAZDA RX 7 with a VIN of JMIFD332 P0200001 through JMIFD332 P0210577 Category S Body Bulletin No 026 93 Date 5 26 93 DESCRIPTION A rattling noise may be heard around the outer door handle area while the vehicle is being driven This is caused by loose door handle nuts REPATR PROCEDURE If a rattling noise is heard replace the original door handle nuts with the replacement parts self locking type nuts Removal and Installation procedures can be found in the appropriate service information Self Locking Nut r Outer Door Handle 94F53145 Fig 1 Outer Door Handle PARTS INF
378. Nm i 95D58647 Fig 2 Earth Ground Bracket Location amp Tightening Torque Fig HESITATION WHILE DRIVING CHECK ENGINE GROUND STRAP CAT F NO 005 97 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 35PM 69 5 95 4 in lbs 7 11 Nm 12 17 ft lbs 16 23 Nm 95E 58648 Ground Strap Location amp Tightening Torque PARTS INFORMATION PARTS INFORMATION TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 New P N 3 Old P N 3 Description Qty w Interchangeability HESITATION WHILE DRIVING CHECK ENGINE GROUND STRAP CAT F NO 005 97 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 35PM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 FDO2 67 E70 FD01 67 E70A Earth Wire 3 1 A 3 3 NOTE Interchangeability A The new part can be used in place of the old part but the old part CAN NOT be used in place 3 3 of the new part
379. OAD TEST OF VEHICLE WITH REPLACEMENT TRANSMISSION ALL SELF TEST ERROR CODES MUST BE REPAIRED CLEARED Test Drive Results After Service Acceptable Unacceptable Service Test Error Codes After Required Road Test Evaluation KOEO CONT KOER AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 22 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM END OF ARTICLE DTC DIAGNOSTIC TROUBLE SHOOTING TIPS MT 0597 07 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER DTC DIAGNOSTICS Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0597 07 Date May 1997 DESCRIPTION The diagnostic procedures for DTCs Diagnostic Trouble Codes in the Workshop manual don t always include the procedure to check related connectors that are within the DTC component s circuit Whenever performing diagnostic procedures always use the wiring diagram in conjunction with the Workshop Manual Check each related connector for the following
380. OOLING SYSTEM CHECK AFFIXING CAMPAIGN LABELS NOTE Procedure E is continued from procedure D 55 After assembling parts follow the instructions below prior to replenishing coolant Measure the concentration of antifreeze in the removed coolant with a hydrometer Tf the concentration is more than 45 use the removed coolant to fill the system purge air from the system and fill the coolant reservoir to the F mark Tf the concentration is 45 or less add 100 anti freeze to the coolant system as specified in the ANTI FREEZE CONCENTRATION TABLE Purge the system of air Use the original coolant to fill the reservoir to the F mark NOTE Coolant refers to the fluid drained from the vehicle Anti Freeze refers to 100 new coolant ANTI FREEZE CONCENTRATION TABLE ll UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Concentration Of Amount of Anti Freeze 3 Anti Freeze 3 To Be Added 3 3 0 55 3 4 4L 3 3 5 10 3 4 1L 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 10 15 3 3 8L 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 15 20 3 3 5T 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 20 25 3 3 1L 3
381. ORMATION TABLE U AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Part Number Description 7 Qty 3 Remarks 3 OUTER DOOR HANDLE RATTLES REPLACE NUTS CAT S NO 026 93 9YBO 40 603 Self Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM Locking Nut 2 3 One Door 3 U WARRANTY INFORMATION Applies to Vehicl Warranty Type Code Customer Comment Code Damage Code Part No of Main Cause Operation No Labor Hours END OF ARTICLE s Covered Under Warranty A 82 99 9YBO 40 603 XX0566R1 One Door XX0566R2 Two Doors 0 3 Hrs One Door 0 4 Hrs Two Doors PRE PAINTING PREPARATION FOR FRONT amp REAR BUMPERS CAT S NO 020 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PAINTING PREPARATION FOR FRONT amp REAR BUMPERS Model s
382. PAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 74 te cover to a container of special adhesive very dealer The adhesive was strapped which clearly indicates that this adhesive adhesive that can be used to carry out the this Recall his Recall parts will h repair proce If Procedure unless you hav Do not attempt to carry out the adhesiv If your t dealer has not received th the Technical Hot Line at 1 800 268 9400 Initial quantities of the Fuel Hos N3A1 13 S70 have already been shipped However pleas 8 ave to b adhesive please contact Kit part number onfirm parts stock with each new customer that books n appointment to have this Recall completed In addition to the above mentioned parts the following dure s ordered depending on which is required A is performed no additional parts order is necessary If Procedure order Thrott B amp C are performed e Water Hose Kit part number N3A1 13 S60 and Filler Cap Kit If Procedure B C order Throttle Water Hose Kit Filler Cap Kit Thermostat Gasket Water Pump Kit part number N3Z1 15 S10B amp D are performed part number N3A1 13 S60 To Determ part number N3Z1 15 S10B p
383. PROCEDURE RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 24 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM PRE CAUTIONS 1 Boost tubes water hoses and fuel hoses should be removed and replaced on the designated side only as shown in the procedure do not remove any joint other than those indicated 2 Do not remove any fuel hose during the check for fuel leakage after replacement please s step 33 If a hose s is removed mistakenly replace the clip s and the hose s with new one s 3 Be sure to use the hoses clips and gaskets designated in this procedure and do not reuse the removed parts 4 When installing the hoses be sure to check their locations in accordance with the instruction and install them correctly PROCEDURE B REPLACEMENT OF FUEL HOSE KIT AND THROTTLE HOSE KIT To be performed on ALL customer sold vehicles NOTE Throttle Hose Kit part number N3A1 13 560 and Filler Cap Kit part number N371 15 S10B must be ordered separately and are not included in Fuel Hose Kit l Start the engine 2 Remove the circuit opening relay 3 After th ngine stalls crank the engine for 15 20 seconds to purge the injectors 4 Turn the ignition switch off 5 Install the circuit opening relay See Fig 32 Circuit Opening Relay Fig 32
384. PTION This bulletin contains diagnostic and repair procedures for the following components Engine Control Units ECU Air Flow Meters Fuel Pumps Alternators Each procedure includes the following 1 Outline Of Diagnostics Parts Requirements And Warranty Application Illustrates the steps from diagnostics through parts return and warranty submission 2 Diagnostic Procedures Step by step testing of the component and circuit 3 Component Check Sheet Details of the customer complaint and events leading to the repair NOTE Proper completion of the check sheets are required for warranty claim submission INDEX SECTION 1 Outline ECU Diagnostics ECU Check Sheet SECTION 2 Outline Air Flow Meter Diagnostics Air F SECTION 3 Low Meter Check Sheet ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Outl Fuel Fuel SECTION 4 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM ine Pump Diagnostics Pump Check Sheet Outline Charging System Diagnostics Alternator and Battery Check Sheet SECTION 5 Warranty Information Refer to the described in appropriate service information for symptoms not this bulletin If further reference is required contact the Technical Hotline in your area ECU OUTLINE OF DIAGNOSTICS PARTS ORD
385. RAAAAAAAAAAAAAAAAAAAA 55 420E 00 3 Meter Hood 3 2 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAA 3 64 471D 00 3 Switch Panel 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 68 4LY OO 3 Switch Panel L 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 68 4MOA 00 3 Arm Rest Trim Lid L 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 69 44XA 00 3 Front Assist Grip R 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU WARRANTY INFORMATION Applies to Vehicles Covered Under Warranty Warranty Type Code A Customer Comment Code 45 Damage Code 9X Part No of Main Cause Operation No Labor Hours S5 210B 00 S0702XRX 0 9 hrs 55 420E 00 TO602XRX 0 6 hrs 64 471D 00 S0805XRX 0 2 hrs 68 ALY 00 XXO510R1 0 5 hrs 68 4MOA 00 XXO510R2 5 hrs 69 44XA 00 XXO510R3 0 4 hrs END OF ARTICLE BROKEN PASSENGER SIDE DOOR GRIP REPLACE GRIP CAT S NO 033 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 34AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN BROKEN PASSENGER SIDE DOOR GRIP Model 5 1993 Mazda RX 7 with a VIN of JMIFD331 P0200001 throug
386. RAKES APPLIED CAT S NO 011 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 25AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RATTLING NOISE FROM DASHBOARD AT IDLE WITH BRAKES APPLIED Model 1993 95 Mazda RX 7 Category S Body Bulletin No 011 97 Date May 19 1997 DESCRIPTION A rattling noise may be heard from the dashboard when pressing the brake pedal at idle This noise is transmitted through the body by the check valve operating in the brake vacuum line Customers complaining of this noise should have the vehicle inspected and if necessary repaired according to this bulletin NOTE Ths noise may occur after performing Brake Vacuum Hose recall campaign 465609 REPAIR PROCEDURE See Fig 1 for components and location pertaining to Vacuum Line Vacuum Pipe Remove And Discard Bolt Loosen From This Side Only SS Install Rubber Mount And Nut Tightening Torque 0 7 1 1 kgf m 5 8 ft lbs 97G51165 Fig 1 Brake Booster Vacuum Line Location 1 Verify the concern RATTLING FROM DASHBOARD AT IDLE W BRAKES APPLIED CAT S NO 011 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 25AM 2 Loosen the two bolts attaching the vacuum pipe to the cowl panel Remove and disca
387. RECTION In order to effectively correct brake judder rotor surfaces must be precisely machined Mazda Canada Inc has evaluated both on and off car brake lathes and has determined that on car lathes are mor precise and greatly reduces comeback repairs The steps necessary for correction of brake judder are as follows BRAKE JUDDER REPAIR CANADIAN CAT P NO 94 06 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 24AM 1 If the vehicle is in dealer inventory and the condition is rotor rust A Clean the rotor surface by driving the vehicle several miles while frequently applying the brakes B If vibration pulsation is still felt processed to step C C Machine the rotor surface enough to remove all rust or surface staining generally 0 1 mm per side NOTE If machining is performed the Service Manager s signature must appear on the repair order 2 If the vehicle has been in service A Verify customer s complaint with a test drive B If brake judder is felt proceed to step C If brake judder is not felt refer to the work shop manual or the NVH manual for additional troubleshooting information C Mark the front wheel s and the lug nut stud with chalk This will determine the original position of the wheel to the rotor Remove the f front wheel 5
388. RES Model 5 1993 Mazda RX 7 Category W Workshop Manual Corrections Bulletin No 034 92 Date 10 26 92 DESCRIPTION Attached are pages for the 1993 RX 7 Workshop Manuals which require corrections for the reasons listed below 1993 RX 7 K 219 K 233 correction to Step 1 Action items These pages have been corrected and their entire repair procedures are listed below CORRECTIONS PAGES K 219 K 231 CORRECTION TO STEP 1 ACTION ITEMS Troubleshooting If a service code number is shown on the SST check for the cause by using the chart Fig 1 related to the code number shown WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM Cod Diagnosed Mem Indicator flashing pattern Condition Point i Engine rpm No input signal from e Wiring from engine control signal ECU unit to EC AT control unit e Engine control unit Speed sensor 1 Revolution e Speed sensor 1 connector sensor E No input signal from Speed sensor 1 Revolution sensor e Wiring from speed sensor 1 to EC AT control unit e Speed sensor 2 resistance e Speed sensor 2 connector e Wiring from speed sensor 2 No input signal from speed sensor 2 to combination meter Yes e Wiring from combination
389. RK PLUGS FOR PISTON ENGINES YEAR MODEL NGK P N MAZDA P N BLISTER PACK 1992 MX 3 1 8L 6 BKR6E BP03 18 110 1992 MX 3 1 6L BKR5E BPO1 18 110 1992 929 COLD TYPE BKR6EVX JE43 18 110 Tx 1992 929 STD TYPE BKR5EVX JE41 18 110 1988 91 929 929S ZFR6A F201 18 110 1989 MPV ZFR6A F201 1B 110 Prod 8701 9623 ZFR6E F285 18 110 Prod 9623 9B01 1990 92 MPV AFR5FE F287 18 110 zx 1993 MX6 626 4CYL BKR5E BP01 18 110 STD TYPE 1993 MX6 626 4CYL BKR6E BP03 18 110 COLD TYPE 1993 MX6 626 V6 ZFR5F F287 18 110 STD TYPE 1993 MX6 626 V6 ZFR6E F285 18 110 1988 92 MX 6 626 ZFR6A F201 18 110 x 1979 82 626 BP5ES 0660 18 110 8AG1 18 110A BP 1979 87 626 BPR5ES 8914 18 110 8AB1 18 110A BP 1986 87 626 Turbo BPR6ES 1690 18 110 x 1990 92 MIATA BKR6E BP03 18 110 x 1986 92 323 BPR5ES11 B601 18 110 x 1990 92 PROTEGE
390. RKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 22 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM E 3 Approx 100 Throttle 3 3 det 8 3 OK w w w www w Is servic Disconnect dropping resistor connector Is resistance of Resistance 10 14 ohms Disconnect negative battery cable 20 seconds Connect battery cable and recheck for servic f resistor 3 Yes 3 3 3 3 3 3 3 3 3 3 Chec from k wiring and connectors EC AT control unit to dropping resistor an OK go to next step not OK repair wiring d or connector 3 3 3 3 3 3 3 No 3 Repl ace dropping resistor 3 Y s3 for at least 7 3 Repl ace EC AT control unit 3 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Intermittent poor connection cod 3 code display ed 3 3 No 3 3
391. RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM Reuse the connector bolts Gasket 94159335 Fig 22 Installation of Fuel Hose on Secondary Fuel Distributor 29 Replace the fuel hose on the return side of the secondary fuel distributor with a new one S Fig 23 NOTE Replace the clip also with a new one Do not use clips other than those included part number below Fuel hose N370 13 415 Clips o9574 3 157 Clip with Pink Colored holder For the direction of the clip claws see Fig 23 Do not place the clip on the pipe bulge 94159336 Fig 23 Return Side of Secondary Fuel Distributor Hose Replacement Place the Clip Claw on the Top Use New Parts RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 18 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM 30 Replace the two vacuum tubes with new ones S 24 Vacuum tube 99351 04150 x 2 pcs 242 al EH 7 S 4 94A59337 an Fig 24 Location of Vacuum Tubes 31 Install the primary fuel distributor and the secondary fuel distributor to th ngine S Fig 25
392. S 1986 RX 7 4 50 4 50 1 1987 RX 7 4 68 1988 RX 7 4A 68 1 1993 RX 7 J T6 J 59 CORRECTIONS 1986 88 RX 7 FUEL PRESSURE RELEASE AND SERVICING FUEL SYSTEM Fuel in the fuel lines remains under high pressur ven when th engine is not running A Before disconnecting a fuel line release fuel pressure from the fuel lines to eliminate the possibility of injury or fire Start the engine 2 Disconnect the fuel pump connector with the engine running Fig 1 WORKSHOP MANUAL CORRECTION FUEL SYSTEM INSPECTION CAT W NO 028 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 02AM Fuel pump cover Fuel pump connector 94C54090 Fig 1 Fuel pump Connector 3 Allow the engine to stall then turn the ignition switch OFF B Use a rag to protect from fuel spraying out when disconnecting the hoses and plug the hoses after removal to prevent leakag System Operation WARNING Before disconnecting any fuel line release the fuel pressure from the fuel system to reduce the possibility of injury or fire Refer to Page 4 50 Hold Pressure Inspection 1 Release the fuel pressur rom the fuel system 2 Disconnect the negative battery terminal 3 Install a fuel pressure gauge between the fuel filter and the pulsation damper
393. SLHVd Seat Belt Extender Availability Application Table 2 Fig WARRANTY INFORMATION 4 TD 5 E D 4 O 4H o D gt O p OGS n 4d x r GH oo gt fy ao OG O N H D H CO 4 H A g OH Ow 4 ENG OH p n o SH O 4 D Q H o0 H wg r S o O gt gt D e d HY 4 0 r Q QE ay z SEAT BELT EXTENDERS DESCRIPTION ORDERING INFO CAT S NO 005 98 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 43PM Information Warranty Type Code A Symptom Code 99 Damage Code 99 Part Number Main Cause Refer to Parts Information Quantity ab Operation Number N A Labor Time N A END OF ARTICLE SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL REPAIRS Model 5 1993 94 Mazda RX 7 Category AD Bulletin No 002 96 Date February 1996 PURPOSE OF THIS INFORMATION 1 Emphasize the importance of proper repair 2 Provide diagnostic tips if repairs are not performed correctly CONTENTS January 1994 M
394. See Fig 2 94D54091 Fig 2 Measuring Fuel Pressur 4 Connect the negative battery terminal WORKSHOP MANUAL CORRECTION FUEL SYSTEM INSPECTION CAT W NO 028 92 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 02AM 5 Connect the terminals of the check connector Yellow 2 pin with a jumper wire 6 Turn the ignition switch ON for 10 sec to operate the fuel pump Point A on Fig 3 PRESSURE 94E54092 Fig 3 Fuel Pressure vs Time Graph 7 Turn the ignition switch OFF and disconnect the jumper wire Point B on Fig 3 8 Observe the fuel pressure after 15 minutes Fuel Pressur Drop less than 20 Kpa 0 2 kg cm 2 8 psi 4e 9 If not as specified perform the following inspection Fuel pump on vehicle inspection Refer to page 4 51 Pressure regulator inspection I Refer to page 4 52 njector on vehicle inspection Refer to page 4 53 TRANSMISSION PAGE J 16 NEW EXTENSION HOUSING DISASSEMBLY INSTRUCTIONS Disassembly Note Extension Housing 1 Temporarily reinstall the shift lever and move the control rod end to the neutral position Fig 4 WORKSHOP MANUAL CORRECTION FUEL SYSTEM INSPECTION CAT W NO 028 92 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 19
395. Text p 34 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 7 Use long needle nose pliers to remove hose clamps and replace the rear throttle body water hose with a new one Remov holders from clamps Attach with two new clamps See Fig 48 Water hose N3A1 13 681A Clamps 99287 1400P x 2 pcs Install New Rear Throttle Body Water Hose Use New Clamps DO NOT DAMAGE 94B Fig 48 Installing New Rear Thrott ter Hose N3A1 13 681A Use New Clamps 8 Replace the throttle body water hose with a new one using two new clamps See Fig 49 Water hose N3A1 13 691A Clamps 99287 1400P 2 pcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 35 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 94C59347 CLD Instali New Throttle Body Water Hose Using Two 2 New Clamps Fig 49 Installing New Throttle Body Water Hose N3A1 13 691A Use Two New Clamps 24 Removal of primary fuel distributor secondary fuel distributor and insulator See Fig 50 1 Loosen the four bolts 2 Loosen the connector bolt from the inlet of the secondary fuel distributor Bolt Fuel Connector 94A59329 Fig 50 Removal of Primary amp Secondary Fuel Distributor amp Insulato
396. This file is available for free download at http www iluvmyrx7 com This file is fully text searchable select Edit and Find and type in what you re looking for This file is intended more for online viewing than printing out so some graphics may not print 100 legibly you can zoom in on them if you need to www iluvmyrx7 com A T NO START AFTER HEAT SOAK WIRE LENGTH INCREASED CAT G NO 001 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 19PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN NO START AFTER HEAT SOAK Model s 1993 Mazda RX 7 A T with a VIN of JM1FD3 P0200001 through JM1FD3 P0210498 Category G Engine Electrical Bulletin No 001 93 Date 7 2 93 DESCRIPTION Hard restart after running the vehicle at high speeds on hot days Vehicle restarts easily after engine compartment cools down This hard start condition is caused when heat from the engine increases the electrical resistance in the starter wire This decreases the amount current received at the S terminal on the starter To correct this problem the starter harness length has been changed and the amount of current applied to the S terminal during starting increased REPATR PROCEDURE If the condition exists install the countermeasure starter wire harness 1 Disconnect the vehicle
397. U1 18 110A BP 1972 76 B1600 BP7ES 0745 18 110 1977 78 B1800 BP 6ES 0259 18 110 8AU1 18 110A BP 1979 B2000 BPR5ES 8914 18 110 8AB1 18 110A BP 1981 87 1980 81 B2000 BPRBES 1690 18 110 _ 1970 1500 BP7ES 0745 18 110 1970 72 1800 BP7ES 0745 18 110 1971 616 BP7ES 0745 18 110 1972 73 618 BP7ES 0745 18 110 Resistor Plug 1974 76 REPU B7EM 2328 18 600 8AH1 18 110A BP 1977 REPU B7ET 3743 18 600 38AF1 18 110A BP 1971 74 RX 2 B7EM 2328 18J600 8AH1 18 OA BP 902 75 RX 3 B7EM 2328 18 600 8AH1 18 OA BP 1976 RX 3 BR7ET 3648 18 600 zx 1977 78 RX 3 B7ET 3743 18 600 8AF1 18 110A BP 1972 78 RX 3 B8EM 2359 18 600 1974 75 RX4 B7EM 2328 18 600 8AH1 18 110A BP 1974 78 RX4 BR7EM 2182 18 600 zx 1974 78 RX4 B7EMV 1757 18 600 E 1976 78 RX4 B7ET 3743 18 600 8AF1 18 1110A BP 1976 78 RX4 BR7ET 3648 18 600 x 1976 78 RX4 BR8ET 3649 18 600 8AF3 18 110A BP 1979 RX 7 B7ET 3743 18 600 8AF1 18 110A BP 1979 RX 7 BR7ET 3648 18 600 1980 RX 7 BR8ET 3649 18 600 8AF3 18 110A BP 1980 RX 7 BR9ET 8344 18 600 E 1981 85 RX 7 4 N201 18 600 8AF2 18 110A BP 1984 85 RX 7 4 N203 18 600 1986 91 RX 7 BUR7EQ N343 18 110 N3X4 18 110 Leading 1986 91 RX 7 BUR9EQ N342 18 110 N3X4 18 110 Trailing 1993 RX 7 BUR7EQP N3A2 A8 110 N3X5 18 110 Leading 1993 RX 7 BUR9EQP N3A1 18 110 N3X5 18 110 Trailing
398. UID IS CLEAN PARTS INFORMATION Recommended Power Flushing Equipment see Service Bulletin ST 000 98 for details PARTS INFORMATION TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAARAAAAAAAAAAAAAAAAY 3 Part Number 3 Description AAAAAAAALBAAARAAAARAAARAARAAARAAAAAA RRAAAARARAARARAA 3 J35944 AMAZ Kent Moore Flusher w Mazda Adaptors 3 90081 M OTC Flusher w Mazda Adaptors 7 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Flushing Fluid 2 U FLUID FLOW amp COOLER LINE FITTING Typical automatic transmission transaxle normal fluid flow amp cooler line fitting locations are located at Fig 4 Refer to applicable WSM for specific details AUTOMATIC TRANS COOLER LINE FLUSHING PROCEDURE CAT K NO 005 98 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM COOLER INLET D COOLER INLET pm LOCATION OF INTERNAL METAL PARTICLES AND DEBRIS ACCUMULATION MESH TYPE BAFFLE 97457521 EN Fig 1 Automatic Transmission Flushing Cooler COOLER IN LINE FLUSH
399. View of Door Checker PARTS INFORMATION TABLE SQUEAKING NOISE WHEN OPENING CLOSING DOOR CHECKER CAT S NO 010 94 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 41AM AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Description 3 Part Number 3 Applicable 3 3 3 New 3 Old 3 3 3 3 Door Checker 3 58 270 3 FDOL 58 270A 3 RX 7 U WARRANTY INFORMATION Applies to vehicles covered under normal vehicle warranty Warranty Type A Customer Comment Code Damage Code 92 Part Number Main Cause 58 270 Quantity 2 Operation Number S1006XRX one side Labor Hours 0 5 Hrs Location Code RHD right side LHD left side NOTE If both door checkers are replaced 2 claims will be required Use the above Operation Number and Location Code when submitting the claims
400. YES 3 3 Internal Inspection Required AAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 3 NO 3 AAAAAAAAAAAAAAAAAAAAAAR 3 3 Repair Refer to the Warranty Repair Guide 3 UAAAAAAAAAAAAAAAAAAAAAAY NO 3 3 Is Vehicle Repaired AAAAAAAAAAAAAAAAAAAKA AAKAAAAAAAAAAAAAAAAAAAAU 3 7 YES 3 3 3 Return To Customer 3 3 AAAAAAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 0 Check M Tips On Line or Call Hotline AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU NO Can Trans Be Repaired ARUBA UNAM Complete A T Check s 3 At Dealer 2 Sheet Request Auth AAAAAAAAALARARARAAARARAAAU 3 orization Order Trans 3 3 YES 3 Replace Trans 2 3 AA AAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Repair Use WSM Refer to the 7 Warranty Repair Guide 3 U AA AAAAAAAAAAAAAAAAAAA NO AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Is Vehicle Repaired AAAAAAA Check M
401. a 20 mm or 13 16 in open end wrench into the slots of the quick coupler then pull the hose out See Fig 1 98B51715 Fig 1 Heater Hoses END OF ARTICLE HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 ARTICLE BEGINNING TECHNICAL Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM SERVICE BULLETIN HEATING SYSTEM TROUBLESHOOTING MANUAL Section The diagnostic Canada duri The diagnostic procedur Model All Mazda Models Category U Bulletin No 93 04 Date September 1993 DESCRIPTION This Service Bulletin contains a new Heating System Troubleshooting Manual that was developed by the Mazda Canada Quality Assurance procedures were developed and tested in ng a Cold Weather Test that took place in February 1993 tested on vehic in which customers had complai ned about a lack of heat for several winters S wer es The ffectiveness of these procedures was confirmed SPECIAL NOTE T Training Co HEATER AND INTRODUCTION A across Nort his same manual will also be used as a hand out for all forth coming urses on Climate Control Systems DEFROSTER TROUBLESHOOTING MANUAL n investigation was conducted using customer vehicles at dealer ships h America over a two year period The investigation was conducted to determine if there were any con cerns that were
402. a at 1 800 222 5500 Also contact the National Highway Traffic Safety Administration s Auto Safety Hotline at 1 800 424 9393 ADDITIONAL INFORMATION The National Highway Traffic Safety Administration operates Monday hrough Friday from 8 00 AM to 4 00 PM Eastern Time For more ct FUEL HOSE MAY LEAK FROM EXCESSIVE ENGINE HEAT Article Text p 2 information call 800 4 impaired call 800 END OF ARTICLE 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 54AM 124 9393 or 424 9153 202 366 0123 For the hearing RADIATOR CAP PRESSURE SET TOO HIGH Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM ARTICLE BEGINNING NHTSA RECALL BULLETIN Model 5 Campaign No Number of Affected Vehicles Beginning Date of Manufacture 23 6 99 1993 Mazda RX7 1994 Mazda RX7 94V094000 DEC Ending Date of Manufacture VEHICLE DESCRIPTION Passenger vehicles DESCRIPTION OF DEFECT r li 4 The radiator cap pressur valv 1994 JAN rel as pressur high thermal this occur FAULT Burned Overheated Burnt out SYSTEM Engine cooling system CONSEQUENCE OF DEFECT If e top of the engine CORRECTIVE ACTION Dea
403. a models Category U Heater amp Air Conditioner Systems Bulletin No 008 97 Date May 19 1997 DESCRIPTION Use a fluorescent A C leak detecting tracer dye and light for finding minute intermittent leaks NOTE Most electronic leak detectors can detect small steady leaks but are ineffective on minute intermittent leaks WHEN USING A C TRACER DYE METHOD 1 Follow the A C tracer dye manufacturers instructions NOTE Different manufacturers have different methods for installing measuring and diagnosing with their particular product CAUTION Use only a tracer dye that is compatible with the type of refrigerant and oil in the vehicle s A C system Tracer dye can lead to misdiagnosis and unnecessary parts replacement if used improperly 2 After repairing the leak clean the area that is covered with A C tracer dye NOTE This will prevent a future technician from mistaking this residue as a current leak 3 When diagnosing an A C leak on a vehicle that previously had tracer dye installed thoroughly clean the suspected area and re verify the leak prior to repairing 4 After repairing the leak evacuate and recharge the system as outlined in the workshop manual NOTE DO NOT add additional A C tracer dye when recharging the system a Flushing or changing he A C oil is not necessary USE OF A C TRACER DYE SERVICE INFO CAT U NO 008 97 Article Text p 2 199
404. able WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 25 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM 3 Drive the vehicle at 50 km h 31 mph and depress the accelerator pedal fully to activate kickdown Stop the vehicle gradually 4 Connect the SST to the diagnosis connector Fig 17 94A 55509 Fig 17 Connecting SST to Vehicle 5 Turn the ignition switch ON 6 Verify that no code numbers are displayed END OF ARTICLE YEAR 2000 COMPLIANCE CAT 01 NO 018 99 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN YEAR 2000 COMPLIANCE Model 5 All Mazda Models Category 01 Engine Bulletin No 018 99 Date May 28 1999 DESCRIPTION Because all Control Units including the Powertrain Control Modules used in Mazda vehicles do not use the day month or year to operate Mazda vehicles are completely immune to the effects of the year 2000 concern END OF ARTICLE BLACK FINISH PEELING FROM INERIOR TRIM REPLACE PART CAT S NO 056 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 33AM ARTI
405. afety related warning LAP BELT EXTENDER listed on the extender must be explained to the customer when th S EXga 2h NEVER USE When lap strap will not adjust snugly to hips When intersection of lap and upper torso straps measured along the lap strap is less than 6 inches from an imaginary center line of occupant s ody NAVAJO and B SERIES O t SEAT BELT EXTENDER Less Than WARNING Front Edge Of Do Not Use Extender Extender Buckle Unless it is physically required in order to wear the vehicle s safety belt If it causes the distance between the front edge of the extender buckle and the center of the occu pant s body to be less than 6 inches Incorrect use of the extender may cause a serious injury Use extender only in the vehicle and seating position it was provided for Remove and stow when not in use by person it was provided for ALL OTHER MODELS 95A57067 Fig 1 Seat Belt Extender amp Seat Belt Extender Warning Labels PARTS INFORMATION SEAT BELT EXTENDER DESCRIPTION ORDERING INFO CAT S NO 032 96 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 41AM 1991 94 NAVAJO amp 1994 97 B SERIES INFORMATION TABLE UAAAKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAAABAAAAAAAA 3 Part Number i 3 ARAAAAAARAAAAAAAAAAAAARAA 3 3 3 9 inch 3 12 inch 3 VIN 3 Se
406. an and retorque main battery ground and bracket mounting bolts bracket used for mounting the ground See Fig 2 a Tightening Torque 7 11 N m 69 5 95 4 in lb b Remove the original ground strap and terminal bracket between the engine hanger and the bulkhead c Install new style ground strap using the original bolts See Fig 3 d Tighten Torque 16 23 N m 12 17 ft lb engine hanger side 7 11 N m 69 5 95 4 in lb engine room bulkhead side 3 Verify repair HESITATION WHILE DRIVING CHECK ENGINE GROUND STRAP CAT F NO 005 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 00AM Harness Ground Tightening Torque 69 5 95 4 in Ibs 7 11 Nm 95C58646 Fig 1 Harness Ground Location amp Tightening Torque Measurement Earth Ground Bracket Tightening Torque 69 5 95 4 in Ibs Battery Cable 16 28 Nm i 95D58647 Fig 2 Earth Ground Bracket Location amp Tightening Torque Fig HESITATION WHILE DRIVING CHECK ENGINE GROUND STRAP CAT F NO 005 97 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 00AM 69 5 95 4 in lbs 7 11 Nm 12 17 ft lbs 16 23 Nm 95E 58648 Ground Strap Location amp Tightening Torque PARTS INFORMATION PARTS
407. an control module ECM and input devices S Figs 14 and 15 ENGINE COOLANT TEMPERATURE SENSOR IGNITION Age SWITCH DATA LINK A RANA MODULE CONNECTOR TFA TERMINAL CHECK CONNECTOR ENGINE COOLANT TEMPERATURE SWITCH 98E51627 Fig 14 Cooling Fan Control System Components SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 18 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 45PM Operation Engine condition A C op Cooling fan No electrical load RC Mm No 1 Engine coolant temperature below 105 C 221 F Cooling fan a No 2 Cooling fan Cooling fan E m No 3 s No ane Engine coolant temperature 105 108 C 221 226 F In 10 min after ignition Engine cool switch is tumed OFF ant tempera Engine coolant tempera ture over 108 ture above 108 C 226 C 226 F F for more than 2 min after ignition before ignition switch is switch is turned OFF Engine cool ant tempera ture becomes lower than 108 C 226 F after igni tion switch is tumed OFF tumed OFF ete E EE EE ME MN NL Engi above 108 C ee NE RS TEE ero on T e se Engine coolant temperature sensor mal function TFA terminal ground
408. an the area with a glass cleaner 5 Remove the protective backing from the stencil 6 Align both ends of the broken grid line with the opening in the stencil and press firmly to attach See Fig Paint Resin On Allow One 1 Minute Repeat Total Three 3 Tlmes Align Open Ends Of Stencil With Grid Lines I 95B51939 Fig 1 Resin Application Location REAR WINDOW DEFROSTER GRID LINE REPAIR PROCEDURE CAT T NO 015 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 42PM NOTE Make sure both ends are aligned prior to attaching 7 Shake the bottle of resin well CAUTION Continuity failure will occur if the ingredients are not mixed completely 8 Brush on the resin overlapping both ends of the broken grid line NOTE Use paint remover to clean brush for future applications 9 Repeat application total of 3 times when the surface is tack free approximately one 1 minute 10 Allow to dry twenty 20 minutes 1 Carefully peel stencil from glass 12 Allow twenty four 24 hours before activating rear defroster PARTS INFORMATION PARTS INFORMATION TABLE 3 Part Number Description 3 0000 88 5067
409. ange Call MASH Hotline Check for intake system leakage or air hose loose or not connected Continuous Over all Ranges Does lack cf power occur over fuil range of engine speeds or above 3 000 RPM exciusivety Repair or replace as necessary Over 3 000 RPM improper secondary T C operation 4 Extension Manifold Throttle Body Intake Manifold Fresh Air Duct NOTE The flow chart above contains numbers inside parenthesis This number corresponds with the step on page 4 Component Troubleshooting and Inspect ion Procedure To Front RENE Turbocharger 98051617 Fig 1 Driveability Troubleshooting Tips Poor Power Idle Hesitates GENERAL TROUBLESHOOTING TIPS SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM TROUBLESHOOTING CHART AARAARARAARARARAAAAAAARAAARAAAARARAARAAAARARAAAARAAAAAAAAAAAAAAA 3 Trouble 3 Possible Cause AARRARARRARARARAARARAARARAARARAARARAARARAARARARAAAAAAARARARAARAAA 3 Engine will not start 7 On older vehicles the injectors may Spark plugs are wet or leak under extremely high pressures fouled developed during the fuel system 3 pressure test 3 Remove and clean plugs x With plugs remove hold the throttle completely op
410. anty Type Code A Customer Comment Code 62 Damage Code OW Part No of Main Cause N3A2 18 9EIB Quantity 1 Operation No K0404XRX Labor Hours Qu 3 HE END OF ARTICLE A T OIL COOLER FLUSHING EQUIPMENT GUIDELINE CAT J NO 96 01 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN A T OIL COOLER FLUSHING Model s All Mazda Models with Automatic Transmission Canadian Section J Automatic Transmission Bulletin No 96 01 Date January 1996 DESCRIPTION The automatic transmission oil cooler must be flushed when a major transmission repair or replacement is performed If the cooler is not flushed properly residual friction material and metal may become dislodged and affect the new transmission s operation A labor operation is established to cover the use of flushing equipment If the transmission oil cooler is not flushed with the proper flushing equipment prior to repair completion and a comeback repair occurs due to clogged oil cooler circuits the repair cost is not warrantable Recommended Power Flushing Manufacturer and Equipment Kent Moore 800 345 2233 J 35944 A Flushing Kit NOTE Flushing Kit includes Chrome Plated Brass Tank One Gallon of J35944 22 Flushing Fluid enough for six flushing operations additio
411. arranty Dealer installed under warranty or retail ORIGINAL EQUIPMENT FACTORY INSTALLED BATTERY Fully covered for the first 12 months and a Pro Rated warranty applies from 13 months to 36 months 1991 and later models Reimbursement for Labor Labor charges related to warrantable repairs on factory installed batteries are fully covered for 36 months The Pro rate amount is based on the retail price of the replacement battery Warranty claims must be submitted with warranty type code E Original Equipment Battery for proper processing Battery warranty on the Original Factory Installed battery starts on the vehicle s INSERVICE DATE Demo Retail The Original Equipment Battery warranty is applicable to batteries installed while in Dealer Inventory 1991 and Later Models 36 Month Pro rate Original Factory Installed Battery Chart I AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Months Customer s Dealer 3 In Use Responsibility Claims 3 3 AAAAAA AAAAAAAA 3 3 0 12 0 100 3 3 13 24 50 50 27 725 236 75 25 3 WARRANTY BULLETIN MAZDA BATTERY WARRANTY CAT G NO 1 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Informat
412. art number N3C1 15 173 part number N321 15 8S20 ine The Correct Repair Procedure The subject vehicles of Recall No also be subject to Recall No launched in July 1994 When the subject vehicles ar in for repair p eas been performed addition to No flow chart on the following page If n 6050 could which was brought e check if recall campaign No 54407 has ot please perform recall No 54407 in 4 based on the Repair Procedures found 60504 Fuel Leakage 54407 Coolant Leakage Me Please follow the flow chart to determine which procedure to perform before beginning repairs on each vehicle YE S M M PCT U JM1FD33 PO200001 210660 3 3 3 Fuel Leakage 3 1993 1994 95 JM 1FD33 R0300001 80400026 AAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Cool lant Leak 3 1993 94 JM1 FD33 PO200001 R0302076 RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM
413. at Position 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 ZZLO 57 660 3 3 All 7 Driver s amp Front 7 3 8 in 3 3 3 Passenger s 3 U 1995 96 PROTEGE INFORMATION TABLE VARARAAAARAAARARAARARARRRRARRRRARRARARARRARARRAAARRAAARARAARRRAARRRR 3 Part Number 3 3 3 3 3 9 inch 3 12 inch VIN 3 Seat Position 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 BCYM 57 63X BCYN 57 63X 3 JMIBA14 S0100001 Driver s amp Front 3 3 3 JMIBB14 T0300001 3 Passenger s 3 3 3 t T0349419 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 1996 PROTEGE INFORMATION TABLE Part Number 3 3 AAKAAAAAAAAAAAAAAAAAAAAAAKAA 3 3 3 9 inch 7 12 inch 3 VIN 3 Seat Position AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 BEYH 57 63X 3 BEYJ 57 63X 3 JMIBB14 T0349420 Driver s amp Front 3 s 3 Passenger s
414. at begins to close and that it closes smoothly and does not hang up 6 If the thermostat fails either of the above tests Replace it 7 Using a filter refill the radiator with engine coolant Recommended Climate Control System Operation If all systems check out O K or through reviewing the Customer Comment Sheet it is determined the system is being operated incorrectly instruct the customer on the proper system operation using the operating guidelines listed below Item Air Intake Selector Fresh Recirculation This selector controls the source of air that enters the vehicle Usually for heating or defrosting the air intake selector should be in the Fresh or outside air mode However if there is a heavy presence of exhaust fumes in the surrounding area it may be necessary to switch to the Recirculation mode It is important to remember to return to the Fresh mode because humidity may build up in the Recirculation mode causing the windows to fog up See Fig 5 Another method to help reduce humidity within the vehicle is to use the Air Conditioning system Its dehumidifying characteristics can be taken advantage of in any situation HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Type cc
415. ation A C O RING REPALCEMENT CAT U NO 95 10 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM K Millenia 1995 Fig 13 1995 Millenia O Ring Identification U DP D UO 3 Pipe O Ring 3 Part Numbers 3 Quantity Ring 3 Size 3 Size D X T 3 and 3 Per 3 3 Code 3 3 7 Kit Numbers 3 Vehicle gt A 8mm 6 9 x 1 78 935 LB51 61 J1X 3 14 z E z oOf8im cCowo65o x 1278 3 L853 61 JIX 3 E 3 12mm 3 10 8 x 2 4 3 LB55 61 JIX 3 11 i 3 3 axial 3 3 3 3
416. ator is internal and not serviceable CALL MASH HOTLINE 4 If cracked porous leakage damaged other CALL MASH HOTLINE A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU tQ iw MAZDA AUTOMATIC TRANSMISSION APPLICATION TABLE 5 OF 6 UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Internal Components NA4A EIS RA4A EL LJ4A EL GF4A EL FA4A EL3 3 NC4A EL RBAA EL 3 G4A EL 2 K 3 3 RA4AX EL 3 G4AX EL3 3 3 Oil Pump 3 CMH CMH 5 CMH 3 CMH 3 CMH 3 2 Clutches i CMH 3 CMH S CMH CMH CMH 3 Pistons 3 CMH CMH 3 CMH CMH CMH ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company
417. ax hot Recirculation fresh fresh 6 Using Figs 3 and 4 for reference ensure the linkages are adjusted properly BLOWER UNIT 94G50589 Fig 3 Blower Unit Linkage Adjustment HEATER UNIT I 94J50590 Fig 4 Heater Unit Linkage Adjustment Item 4 Coolant By passing the Thermostat Thermostat Stuck HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM 1 Drain the engine coolant from the radiator 2 Remove the thermostat from the thermostat housing 3 Visually inspect the coolant passages and thermostat housing for any casting debris 4 Feel around inside the thermostat housing for any foreign materials especially in the area around the heater pipe outlet If present remove any casting sand or debris which may be blocking the coolant passages or causing the thermostat to stick open 5 Verify the operation of the thermostat using the appropriate workshop manual NOTE In addition to the procedure to check for proper thermostat opening the following check must be performed to ensure the thermostat is closing properly When the thermostat has opened fully continue to bring the water to a boil When the water has reached a boil remove the thermostat from the water and set it on the work bench Closely watch as the thermost
418. bolts three pieces Tightening Torque 160 230 kgf cm 139 199 in 1bf Vacuum tubes 10 and 11 N3A4 20 344 x 2 pcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 23 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM 0000 9 CO y SI Y Orange NS 94159343 Fig 30 Installation of Vacuum Tubes 35 Assemble the pans in the reverse order of removal 36 Affix the recall label No 60504 onto the driver s side door for future confirmation that the campaign has been completed on this vehicle 8 Fig 31 Recall Label 60504 94J59344 Fig 31 Recall Label 60504 Identification FUEL HOSES AND COOLING COOLANT SYSTEM REPLACEMENT PROCEDURE RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 24 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM PRE CAUTIONS 1 Boost tubes water hoses and fuel hoses should be removed and replaced on the designated side only as shown in the procedure do not remove any joint other than those indicated Do not remove any fuel hose during the check for fuel leakage after replacement please s step 33 If a hose s is removed mistakenly replace the clip s and the hose s with new one s
419. c Labor Operatio Rear Brakes Disc P Rear Brakes Pad s Rear Brakes Pad s Rear Brakes Disc P Rear Brakes Pad s Rear Brakes Pad s Rear Brakes Disc P n Plate n Plate Rear Brakes Pad s Rear Brakes Pad s Rear Brakes Disc P Plate Plate Plate Plate Plate Plate Plate Plate Plate Plate Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM late s R amp R one PO208ARX 0 4 s R amp R bot PO208BRX 0 6 s Machine PO214AMX 0 7 s achine PO214BMX 1 2 side hrs h sides hrs on vehicl one sides hrs on vehicle hrs P0209ARX 0 4 R amp R both sides PO214BRX 0 5 A M B R amp R one sides A t B late s R amp R one P0208ARX 0 3 s R amp R bot PO208BRX 0 4 s Machine P0214AMX 0 7 5 achine PO214BMX 1 2 rs nrs side hrs h sides hrs both sides on vehicl hrs on vehicle hrs P0209ARX 0 3 R amp R both sides PO214BRX 0 5 A M B R amp R one sides A ju B late s R amp R one P0208ARX 0 4 s R amp R bot PO208BRX 0 5 s Machine P0214AMX 0 7 5 achine PO214BMX 1 2 nrs nrs side hrs h sides hrs on vehicl one sides both sides
420. cable See Fig 5 94H59318 Fig 5 Removing Accelerator Cable amp the Cruise Cable 16 Raise the extension manifold and disconnect the following harnesses vacuum tubes and hoses from the side indicated by the arrow only See Figs 6 7 amp 8 Harnesses Inlet Air Temperature Sensor AB Solenoid ISC Valve 5 Vacuum Tubes EGR Vacuum Hose ACV Vacuum Hose Purge Hose Double Throttle Control Hose Double Throttle Control Actuator Hose tox 0X ab Hoses Water Hose RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Pressure Sensor P Hose EGR Vacuum Hose 94159319 Fig 6 EGR amp ACV Vacuum Hose Water Hose amp Pressure Sensor Fig 7 Hose amp Vacuum Tubes Identification 94C59321 Jg Fig 8 Switch Identification 17 Remove th xtension manifold and throttle body RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM NOTE Cover exposed intake holes with shop towels Torque for re tightening the bolt Tightening Torque 160 230 kgf cm 139 199 in lbf
421. chnicians with credentials dated after April 19th 1993 will be considered trained by an EPA approved certifying program Snap On Tools Corporation 2801 80th Street Kenosha Wisconsin 53141 1410 414 656 5200 Approval Date 3 30 93 Texas Engineering Extension Service San Antonio Training Division The Texas amp M University System 9350 South Presa San Antonio Texas 78223 4799 512 633 1000 Approval Date 3 30 93 Waco Chemicals Inc 12306 Montague Street HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Pacoima California 91331 818 897 3018 Approval Date 7 13 93
422. control module 5 Install in the reverse order of removal Tighten Nut A Torque to 7 9 10 7 N m 80 110 kgs cm 70 95 in lbs 98 151622 Fig 7 Cooling Fan Control Module INSPECTION 1993 RX 7 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 With the cool Artic le Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM an control 1 the voltage at each terminal of tive ground the nega ing Po the c lead to the each terminal oi 2 I are correct systems are normal there is any incorrect inspect related systems the connector replace the cooli onnector module connector connected measur Using a voltmeter See Figs 8 thru 10 fan control module ng 98A51623 Fig 8 Fan Control Module Connector Terminal Locations Terminal Voltage Engine cooi Engine coot ant tempera ant tempera ture for cook ing fan ture switch Engme coolant temperature below 108 C 226 F Engine coolant temperature above 108 C 226 F 98F51743 Fig 9 Termin Cooling fan relay No 2 4 Cooling fan relay No 2 4 NEN J Ground Ground al Voltage Chart A J Cooling fan not operating During cooling fan operating Below 1 0 body an
423. coolant switch connector See Fig 71 7 Remove the surge tank hose from the thermostat cover 8 Remove the thermostat cover Remove the thermostat Install thermostat with new gasket Gasket N3C1 15 173 CT NOTE Ensure that the jiggle pin is in the 12 00 o clock position RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 50 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM disconnect low coolant switch thermostat cover 94C 59354 thermostat coolant level sensor Fig 71 Jiggle Pin Identification 49 Install a new coolant level sensor and gasket Level sensor Included in Kit Gasket Included in Kit 50 Install the thermostat cover NOTE Install water level sensor connector bracket 51 Connect the coolant level sensor 52 Install alternator bracket pulley and belt in reverse order of removal See Fig 67 53 Install new upper radiator hose RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 51 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Radiator hose Included in Kit 54 Install air cleaner and fresh air duct PROCEDURE E C
424. d greatly reduces comeback repairs The steps necessary for correction of brake judder are as follows VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM 1 If the vehicle is in dealer inventory and the condition is rotor rust a Clean the rotor surface by driving the vehicle several miles while frequently applying the brakes b If vibration pulsation is still felt processed to step c c Machine the rotor surface enough to remove all rust or surface staining generally 0 1 mm per side NOTE If machining is performed the Service Manager s signature must appear on the repair order 23 If the vehicle has been in service de a Verify customer s complaint with a test drive b If brake judder is felt proceed to step c If brake judder is refer to the work shop manual or the NVH manual for not felt additional troubleshooting information Cu Mark the f ront wheel s and the lug nut stud with chalk This will determine the original position of the wheel to the rotor Remove the front wheel s NOTE A high majority of brake judder is due to DTV of the front rotors Customer complaints of brake judder are most often corrected by machining the front rotors only d Mea
425. d Cond Milky Burnt Particlees Sludge Normal Trans Fluid Level High Low Normal Trans Leaks Yes list area s If yes Engine Electrical System Battery Voltage engine running Volts KOER Key On Engine Off Key On Engine Running TEST RESULTS LA4A EL Transmission Only e Ty eS aR Problem Category Codes _ Leaks Fluid Cond __ Driveability__ Unusual Noise__ list codes if yes TOM Line Pressure Stall Test Results Line a Kgf psi mo numo AQS RECOMMENDATIONS Did You Use The Quick Diagnostic Chart Il In The WSM Yes Was It Useful Yes__ No Contact Regional Hotline For Assistance Yes _ No__ poe di list person contacted if yes date Recommendation Normal Condition Repair Trans Exchange _ ff MASH Authorization Number 94454106 Automatic Transmission Check Sheet AUTOMATIC TRANSMISSION DIAGNOSTIC PROCEDURES CAT K NO 002 94 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM Symptom Duplicated Listen To Customer Road Test If Complaint Necessary Drive Other Vehicle To Confirm Normai Operation Normal Condition NO Contact Service Manager Or Advisor NO
426. d insert the positive lead in output voltage while all input voltages When the B Battery positive voltage Engine coolant tem perature switch Cooling fan relay Refer to F 146 1 Cooling fan relay TFA terminal of data link connector is grounded Refer to F 146 1 Below 1 0 Cooling fan control module terminal J Ground Below 1 0 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Fig 10 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM B Battery positive voltage Terminal Signal Connected to Test condition Voltage Possible V malfunction ENCOES ERE prec A E BEA EC MADRE BESSER o Power supply Ignition switch OFF Below 1 0 Main relay Ignition switch ON B Power supply Condenser Battery Constant A C fuse fan 98G51744 Main relay Terminal Voltage Chart K P COOLING FAN RELAY NO 1 2 3 4 1993 RX 7 INSPECTION 1 Disconnect the cooling fan relay 2 Apply battery positive voltage and ground to terminals A and B of the cooling fan relay See Fig 11 3 Check continuity of the relay TERMINAL CONTINUITY TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Operation 3 A Type Terminals D E 3 3 3 B Type
427. d left then slowly insert straight into the assembly Refer to Fig 2 and Fig 3 Avoid forcing the connection or mis alignment AIR CONDITION MALFUNCTION HAZARD SWITCH CONTACTS CAT U NO 95 09 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 20PM Align Assembly Slightly Wiggle Connector Left and Right Then insert Straight 94F 59381 Fig 2 Correct Installation of Male Connectors This Position After Aligning Will Damage Push Straight Pins Until Connection 94G59382 Is Complete Fig 3 Installation of Male Connectors HARNESSES 1 DO NOT STRETCH harnesses to connect connectors 2 Route harnesses to provide slack in harness and no stress on connector Refer to Fig 4 Fig 4 AIR CONDITION MALFUNCTION HAZARD SWITCH CONTACTS CAT U NO 95 09 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 20PM Do Not Stress Harness Allow Slack When Lib MAT 94H59383 Correct Installation of Harness WARRANTY INFORMATION Applies to verified customer complaints on vehicles covered under normal warranty Refer to the SRT Microfiche for warranty term information Warranty Type A Symptom Code 60 Damage Code 9G Part Number Main Cause F
428. de Place the fuel distributor side clip claws on the top and the other one on the bottom For the directions of the clip claws see Figs 20 and 21 Insert the hose to the pipe bulge Match the edges of the clip and the hose end Replace all hose clips with new ones Do not use clips other than those included part number below Be care ul not to place the clip on the pipe bulge Clip N3Z1 13 157 x 2pcs with Red colored holder Protector N3B7 1 3428A RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 16 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM Place the fuel distributor side clip claws on the top and the other one on the bottom 94G59333 Insert the hose to the pipe bulge NO CLEARANCE Match the edges of the clip and the hose end Fig 20 Installation of Clips on Hose Install the protector Protector foci AU Tuo 5 f 94H59334 Fig 21 Installation of Protector 28 Install the fuel hose on the secondary fuel distributor See Piga 22 NOTE Place the connector stopper on the secondary fuel distributor body then tighten the connector bolts Tightening Torques 240 360 kgf cm 208 312 in lbf Use new gaskets Gasket N236 13 483 x 2pcs
429. e During electrical cocling fan FA iernat o dagnoss connector ss Beiow 10V qon swich ON g ovnged Ware Engine coolant temperature 20 C 1687 Apmox 25v gawan swich ON tharmosensor arm ul 7 Below Qv Tone pedal released 075 125 CENT Sensor Nar ow range pedal lully depressed BEL Constant EEJ Constant Accelerglo pedal released vy Acceleralor pedal luity depressed Pas Trroins opewng above 1 8 Engine cool ani lemp below 104 7 gon seien ON E Engine speed 1500 3300 m xw gation wich ON Throttle Constant 50 mnmon swich ON ite Temp Seow 100 C 221 Ve Temp Above 100 C 1212F j Engine speed J M Beiow 3250 rpm EGA ymin EGA valve operates A Cantons only EGA valve does nor Opere DAL way we Pull the parking brake Tanada oniy Tutngtn OFF Release ine parking _ Lifurnigni ON Engine speed above 3250 rpm Sole valve nino smicn ON elet 1 Wanian amicr ON mermosensos aler warm up a m s 1 94454056 Fig 1 Wiring Diagram Revision Page 37 WIRING DIAGRAM CORRECTIONS PAGES Z 37 amp Z 40 CAT Z NO 008 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunda
430. e to prevent 94H59342 Fig 63 Seven Fuel Leakage Areas 34 Install the vacuum pipe assembly Replace the vacuum tubes 4 5 6 7 10 and 11 with new ones 2 Connect the hoses 3 14 to the vacuum pipe assembly 3 Connect the coupler of each solenoid valve 4 Install the vacuum pipes to the engine by tightening the bolts three pieces Tightening torque 160 230 kgf cm 139 199 in lbf Vacuum tubes 10 and 11 N3A4 20 344 x 2 pcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 45 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 0000 9 OW Orange Water hose ZA 6 White e D OUT 0m 94159343 Fig 64 Installation of Vacuum Tubes 35 Assemble the parts in the reverse order of removal PROCEDURE C REPLACEMENT OF THE FILLER CAP KIT NOTE Procedure C is continued from procedure B The parts listed in this procedure must be ordered separately and are not included with the Fuel Recall Parts Kit 36 Loosen the bolts of the filler cap body Remove and discard the body and cap Replace body cap and O ring with new ones from kit See Fig 65 Kit Part Number N321 15 S10B a gt 94D59348 Fig 65 Replacing Body Cap amp O Rings RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p
431. e Fig 5 for O Ring Identification A C O RING REPALCEMENT CAT U NO 95 10 MX 5 1994 96 Fig 5 1994 96 MX 5 O Ri Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 A Fication dentii ng 1988 92 626 MX 6 O RING DESCRIPTION TABLE 07 03AM 3 Quantity 3 Per 3 3 Vehicle 3 3 3 5 3 3 1 3 3 3 1 cQ 3 Pipe 3 O Ring 3 Part Numbers Ring 3 Size 3 Size DX T 3 and 3 Code 3 3 3 Kit Numbers AAAAAAAAAAAAAAAAAAAAAAAAAAA AAA AAA AAA AAA AAAAAAAAAAAAAAARAAAAAAAAAAAA 3 A 3 8mm 3 ESIR 18 1 LB51 61 J1X 3 D i 12mm 10 8 x 1 78 3 LB54 61 J1X 3 F 16mm 14 0x 1 78 3 LB56 61 J1X
432. e appropriate service information for instructions 5 Start the vehicle and raise the RPM to 2500 6 Connect a battery load tester VAT 40 70 or equivalent 7 Apply a load equal to the alternator rating The generated voltage should be 14 1V to 14 7V LOAD TEST RESULTS Over 14 7V Replace Alternator Under 14 1V Check for resistance between the battery and ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 16 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM terminals B and S f resistance is present repair the damaged harness and retest lf the voltage is still below 14 1V replace the alternator 14 1V to 14 7V No trouble with the alternator or battery ALTERNATOR AND BATTERY CHECK SHEET Dealer Name Technician Number Vehicle Year Model M T A T VIN Mileage Repair Order Number Repair Date 1 Customer Complaint 2 Was the customer s complaint verified Yes No 3 Reason for replacement Alternator output or battery voltage was out of spec Yes No 3 Reading Factory Spec 3 AAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAALAAAAAAAAAAABAAAARAAAARRARAAA Output Voltage 3 3 AAAAAAAAAAAAAAAAAAA
433. e check f the intake manifold then When reassembling step cut position o ACV ightening torque of the nuts in the ACV 45 See Fig 45 a new one valve in the attach the Make sure that the wire harnesses of the solenoid valve will not touch the ACV RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 32 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 94159327 Fig 45 Removal of Relief Air Hose amp Vacuum Tubes 23 Move the vacuum pipe assembly toward the steering shaft side See Fig 46 1 Loosen the thr bolts that attach the vacuum pipe to the ngine S letter C in Fig 46 2 Disconnect the coupler from the solenoid valve attached to the vacuum pipe 3 Remove the vacuum tubes water hose and fuel hoses cutting the fuel hoses off at the position marked with scissors makes the work easier See Fig 46 NOTE Do not remove hoses other than 1 14 Remove the hoses on the sides indicated by arrows in Fig 46 Be careful not to damage any pipes When removing the hoses do not use any spray type lubricant 4 Move the vacuum pipe assembly toward direction D 5 When reassembling replace the hoses 1 2 3 4 5 6 7 8 10 and 11 with new ones RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CAN
434. e edges of the clip and the hose end Fig 54 Installation of Clips on Hose Install the protector Protector foci AU Tuo 5 f 94H59334 Fig 55 Installation of Protector 28 Install the fuel hose on the secondary fuel distributor See Fig 56 NOTE Place the connector stopper on the secondary fuel distributor body then tighten the connector bolts Tightening Torque 240 360 kgf cm 208 312 in lbf Use new gaskets Gasket N236 13 483 x 2lpcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 39 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM Reuse the connector bolts Gasket 94159335 Fig 56 Installation of Fuel Hose on Secondary Fuel Distributor 29 Replace the fuel hose on the return side of the secondary fuel distributor with a new one S Fig 57 NOTE Replace the clip also with a new one Do not use clips other than those included part number below Fuel hose N370 13 415 Clip 8574 13 157 For the direction of the clip claws see Fig 57 Do not place the clip on the pipe on the bulge 94159336 Fig 57 Return Side of Secondary Fuel Distributor Hose Replacement Place the Clip Claw on the Top Use New Parts RX 7 FUEL LEAKAGE RECALL CAMP
435. e ground circuits This condition affects the fuel control system Customers complaining of this concern should have the vehicle inspected and if necessary repaired according to this bulletin REPAIR PROCEDURE 1 Clean and retorque harness ground See Fig 1 a Locate ground on left side of engine mounted to bracket behind A C compressor Refer to the applicable BETM or wiring diagram b Tightening Torque 7 11 N m 69 5 95 4 in lb 2 Clean and retorque main battery ground and bracket mounting bolts bracket used for mounting the ground See Fig 2 a Tightening Torque 7 11 N m 69 5 95 4 in lb b Remove the original ground strap and terminal bracket between the engine hanger and the bulkhead c Install new style ground strap using the original bolts See Fig 3 d Tighten Torque 16 23 N m 12 17 ft lb engine hanger side 7 11 N m 69 5 95 4 in lb engine room bulkhead side 3 Verify repair HESITATION WHILE DRIVING CHECK ENGINE GROUND STRAP CAT F NO 005 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 35PM Harness Ground Tightening Torque 69 5 95 4 in Ibs 7 11 Nm 95C58646 Fig 1 Harness Ground Location amp Tightening Torque Measurement Earth Ground Bracket Tightening Torque 69 5 95 4 in Ibs Battery Cable 16 28
436. e it arrives at America Kowa Seiki Inc no later than October 31 1997 NOTE DO NOT SEND YOUR V3 0 CARD You are to use this card with your NGS tester while your older card is being updated Your older card will be returned to you if you miss the October 31 1997 cut off date and a new card with V4 0 will automatically be shipped to you Your reprogrammed V4 0 card will be shipped to you no later than November 14 1997 NEW V4 0 NGS CARD AND REPROGRAMMING OF V2 02 CARD CAT ST NO 004 97 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 39PM Store card in plastic cover Keep card dry Do not expose card to direct YO U R sunlight or extreme temperature DEALER CODE Do not bend or drop 2390 DEALER NAME XYZ MAZDA CITY STATE D AA Zona MA Made in the U S A by Hickok Incorporated 97D52186 Fig 1 New Generation Star Tester Card Identification END OF ARTICLE NON FACTORY ACCESSORY INSTALLATION PRECAUTIONS MT 0897 09 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 39PM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER NON FACTORY ACCESSORIES Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0897 09 Date August 1997 DESCRIPTION Do not s
437. e present remove the tape from the overflow hole and install the pressure cap 60 Affix the Campaign Label number 54407 and number 60504 onto the driver s side door for future confirmation that the campaign has been completed on this vehicle S Fig 74 Recall Label 54407 and 60504 94F 59357 Fig 74 Recall Label 54407 amp 60504 Identification WARRANTY INFORMATION REPAIR CONTENT FUEL HOSE AND COOLING SYSTEM WARRANTY TABLE 3 With Coolant Without Coolant 3 Fuel Hose d 3 3 Leak 2 Leak 3 3 EAE ASS SR AR 3 Warranty Type 7 s 5 RRAAARAARAARKAAAAAAAAAARARARAAARAAARAAARAAARAAAAAAAAAAARARARAARAAAAA 3 Recall No 3 60504 3 60504 3 60504 E a 5 3 Process Code 3 3 3 3 AAAARAAAAAAAAAAAAARARAAAAAAAARARAAARARAARAAAAARAAAARARAAARARAAARARAA RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 54 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM 3 Labor Hours 3 4 6 Hrs 3 3 2 Hrs 2 4 Hrs 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Replacement N3A1 13 S70 3 N3A1 13 S70 3 N3A1 13 S70 3 3 Part No 3 3 2 ARAAAAAAAAAAAAAA
438. e the integrity of the cooling system can be compromised Repeated operation of the vehicle in this manner may produce cooling system leaks Under some circumstances the leaking coolant mixture can collect on the top of th ngine where some of the water can evaporate increasing the concentration of the coolant If coolant then leaks onto the exhaust manifold an engine compartment fire could be the result Your RX 7 is equipped with a water level sensor that warns you of low coolant levels with both a warning light and accompanying buzzer In most cases you would be warned of a low water level prior to the point where enough coolant had been leaked to present any serious risk of fire Please make an appointment at your Mazda dealer to have the required repairs performed at no charge to you RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 30 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM If you have moved or no longer own the vehicle please complete the enclosed Change of Address Ownership pre paid postcard as soon as possible so we may update our records and or notify the current owner Should you have any questions regarding this program please contact our Customer Relations toll free number 800 222 5500 If your dealer or distributor does not remedy the d
439. e underside of the hood as shown See Fig 32 57 Affix coolant concentration label to air cleaner housing See Fig 32 RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 26 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Install Coolant Concentration Label ATTENTION COOLANT CONCENTRATION MUST BE KEPT AT 45 OR HIGHER example 45 or higher coolant 55 or iower water All Vehicles Install Recall Label On Inside Of Driver s Door Vehicles With Replaced Water Pump Install An Additional Recall Labet Under Hood On Driver s Side 98E51676 Fig 32 Coolant Concentration Label 58 Place correction sticker over th xisting Mixture Percentage table in the vehicle owner s manual pg 7 15 PARTS INFORMATION An initial allocation of parts will be drop shipped to dealers with their scheduled stock order SSO beginning Monday August 1 through Friday August 5 The total number of filler cap kits and throttle water kits to be distributed will be equal to 50 of the combined number of subject vehicles registered in the dealer s assigned market area and in inventory The total number of thermostat gaskets and water pump kits to be shipped will be equal to 50 of the anticipated failure rate 50 of RECALL CAMPAIGN 54407 COOLANT LEAK 544
440. ecific model and replace wiper motor if necessary 3 To prevent wiper motor binding When wiper blades become stuck to the windshield due to freezing heavy snow build up or non use for long period follow the procedures described below WIPER BLADES INFORMATION TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAR 3 Condition Action 3 ARAAAAAARAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Wiper blades will not move becasuse Remove ice or snow Confirm 3 3 of freezing or heavy snow build up that blades are free 3 Wiper blades stuck to windshield 3 Carefully raise blades from 3 3 because of long term non use 3 glass being careful not to 3 3 3 damage them 2 U CAUTION NEVER operate the wipers when the windshield is dry Squirt washer fluid on the glass before using the wipers to clean the windshield Service Managers and Service Advisors should relay the following to customers with this concern FRONT WIPER MOTOR OPERATION INSPECTION CAT 15 NO 0
441. ect the jumper wire from the check connector Verify that the cooling fan operates at low speed 15 Turn the ignition switch to ON 16 Verify that the cooling fan stops 8 12 seconds after the ignition switch is turned to ON 17 If not as specified replace the cooling fan control module COOLING FAN CONTROL MODULE 1994 RX 7 REMOVAL INSTALLATION 1 Remove the ECM 2 Disconnect the cooling fan control module connector 3 Loosen nut A as shown See Fig 7 4 Remove the cooling fan control module 5 Install in the reverse order of removal Tighten Nut A Torque to 7 9 10 7 N m 80 110 kgs cm 70 95 in lbs INSPECTION 1 With the cooling fan control module connector connected measur the voltage at each terminal of the connector Using a voltmeter ground the negative lead to the body and insert the positive lead in each terminal of the connector 2 If there is any incorrect output voltage while all input voltages are correct inspect related systems See Figs 8 thru 10 When the Systems are normal replace the cooling fan control module SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 20 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 45PM COOLING FAN RELAY NO 1 2 3 4 1994 RX 7 INSPECTION 1 Disconnect the cooling fan relay 2
442. ectly on the outside of the water pump at bolt A See Fig 70 94B59353 Fig 70 Oil Metering Line Retaining Clip Identification 46 Disconnect the low coolant switch connector See Fig 71 7 Remove the surge tank hose from the thermostat cover 8 Remove the thermostat cover Remove the thermostat Install thermostat with new gasket Gasket N3C1 15 173 CT NOTE Ensure that the jiggle pin is in the 12 00 o clock position RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 50 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM disconnect low coolant switch thermostat cover 94C 59354 thermostat coolant level sensor Fig 71 Jiggle Pin Identification 49 Install a new coolant level sensor and gasket Level sensor Included in Kit Gasket Included in Kit 50 Install the thermostat cover NOTE Install water level sensor connector bracket 51 Connect the coolant level sensor 52 Install alternator bracket pulley and belt in reverse order of removal See Fig 67 53 Install new upper radiator hose RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 51 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC
443. ed and if necessary repaired according to this bulletin NOTE Ths noise may occur after performing Brake Vacuum Hose recall campaign 465609 REPAIR PROCEDURE See Fig 1 for components and location pertaining to Vacuum Line Vacuum Pipe Remove And Discard Bolt Loosen From This Side Only SS Install Rubber Mount And Nut Tightening Torque 0 7 1 1 kgf m 5 8 ft lbs 97G51165 Fig 1 Brake Booster Vacuum Line Location 1 Verify the concern RATTLING FROM DASHBOARD AT IDLE W BRAKES APPLIED CAT S NO 011 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM 2 Loosen the two bolts attaching the vacuum pipe to the cowl panel Remove and discard brake booster side bolt only 3 Install a rubber mount into the attaching bolt hole 4 Tighten rubber mount into the firewall Tightening Torque 0 7 1 1 kgf m 5 8 ft lb 5 Install vacuum pipe to the rubber mount retighten bolt loosened in step 2 al Tightening Torque 0 7 1 1 kgf m 5 8 ft lb PARTS INFORMATION PARTS INFORMATION TABLE 3 Part Number 3 Description Oty 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 F285 13 363 Rubber Mounting 3 AAAAAARAAAAAAAAAAAAAAAAAAAAAA
444. ees C 194 degrees F The information in this bulletin is provided to answer customer questions regarding occasional wiper motor perceived problems and prevent unnecessary wiper motor replacement F Motor Damage Zone 752 De 302 FESSES Senet B Circuit Breaker hi 5 Operation Zone BU od ante de rer is v z Motor Operation 93B53778 Time Fig 1 Motor Temperature amp Motor Damage Zone Chart CUSTOMER NOTE FRONT WIPER MOTOR OPERATION INSPECTION CAT 15 NO 070 88 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 31PM 1 To prevent wiper motor binding a Remove ice or snow build up from windshield with a suitable tool b Confirm the wiper is free by carefully raising blades from glass c NEVER operate wipers on dry windshield 2 If the wiper operation stops a Guide the vehicle to the side of road and stop b Turn wipers OFF c Wait approximately 5 minutes and turn the wiper switch ON If the wipers activate the wiper motor and circuitry are functioning properly circuit breaker activated If the wipers fail to activate proceed to your nearest dealer when you can safely drive the vehicl TECHNICIAN S NOTE If the wiper motor does not operate check the wiper motor circuit Refer to Workshop Manual for the sp
445. efect without charge within a reasonable amount of time you may wish to notify the Administrator National Highway Traffic Safety Administration Washington D C 20590 or you can call their toll free Auto Safety Hotline at 800 424 9393 Residents of Washington D C may call 366 0123 Our goal at Mazda is to build and maintain only the highest quality products Please accept our apologies for any inconvenience this may cause you Sincerely Mazda Motor of America Inc END OF ARTICLE RECONDITIONED ANTI FREEZE CAT E NO 002 96 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RECONDITIONED ANTI FREEZE Model 5 All Mazda Models Category E Cooling System Bulletin No 002 96 Date June 27 1996 DESCRIPTION Mazda does not recommend the use of reconditioned anti freeze Mazda recommends ethylene glycol base coolants for all Mazda aluminum engines Although reconditioned anti freeze is available this product may contain silicon particles which may be abrasive to the water pump seal Additionally reconditioned anti freeze may con
446. em controls the electrical fan speed by ECM This system consists of the cooling fan cooling fan relays cooling fan control module ECM and input devices S Figs 3 and 4 ENGINE COOLANT TEMPERATURE COOLING FAN 1 AE sumi P DATA LINK cuc LEA MODULE CONNECTOR TFA TERMINAL LA CHECK CONNECTOR ENGINE COOLANT TEMPERATURE SWITCH 98E51619 Fig 3 Cooling Fan Control System Components Fig 4 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC 221 F Engine condition No electrical load Engine coolant temperature below 105 C Saturday August 25 2001 09 39AM switch ON In 10 min after ignition switch is tumed OFF Engine coolant tempera ture above 108 C 226 F for more than 2 min before ignition switch is turned OFF function 98E51742 Cooling Fan Control System Operation SYSTEM INSPECTION 1 2 Turn the ignition switc 3 Turn the ignition switc 4 Ground the check connect 5 Up to VIN JM1 FD331 verify that the cooling fa seconds after t 6 Verify that the engine coolant temperature is below 80660 Engine coolant temperature 105 108 C 221 226 F Engine coolant temperature above 108 C 226 F Engine coolant temperature En
447. emove Earth Ground Pressure Sensor Brake Rs Booster dp S A S g EGR Vacuum Hose ACV Vacuum Hose ABV Hose Double Throttle Control Actuator Hose Boost Sensor Hose PCV Hose 1 Double Throttle Control Hose 2 Purge Control Hose ACV Vacuum Hose 3 Vacuum Chamber EGR Vacuum Hose Hose Double Throttle Control Actuator Hose ACV Hose EGR Hose Port Port 98 151648 Fig 4 Extension Manifold NOTE Use the above illustration to determine hose location 14 Remove the bolts from the pressure chamber to remove the tank RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM See Fig 5 Remove Pressure Chamber NN 98451649 Fig 5 Pressure Chamber Removal 15 Remove the bolts from the duty solenoid See Fig 6 Duty Solenoid Remove Bolts From Duty Solenoid 98E51650 Fig 6 Duty Solenoid Bolt Removal 16 Remove the accelerator cable and cruise cable See Fig 7 98F51651 RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Fig 7 Accelerator Cable Removal body Shift the 18 Raise the ex and vacuum tubes Harnesses Inlet Air T
448. emperatur 17 Remove the bolts and nuts from the extension manifold and throttle throttle body tension manifold and remove the following harnesses AB Solenoid ISC Valve Vacuum Tubes EGR Vacuum Hose ACV Vacuum Hose Purge Hose Double Throt Double Throt sensor tle Control Hose tle Control Actuator Hose RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Extension Manifold Water Hose Throttle Body Remove Water Hose From This Side 98G51652 Fig 8 Harness and Vacuum Tube Removal 19 Remove th xtension manifold and throttle body NOTE Cover exposed intake holes with shop towel 20 Remove the air intake pipe bracket See Fig 9 Remove NN Bracket S 98H51653 Fig 9 Air Intake Pipe Bracket Removal 21 Replace the front throttle body water hose with a new one and RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM attach it with two new hose clamps See Fig 10 NOTE Holder must be removed from clamps Install Throttle Body Hose Using Two 2 New Clamps 98151654 Fig 10 Install Throttle Body Hose 22 Insta
449. en and crank 3 3 3 3 the engine to dechoke DO NOT REPLACE THE INJECTORS njectors will not leak under normal stem pressure he PCM may have been damaged during he fuel leakage test if the proper 3 rocedure was not followed To test he PCM 3 Connect a jumper wire from the pump terminal in the diagnostic i connector directly to a good j ground not in the connector 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Tu H s Engine does not get fuel Cranks but will not start TO ct H Crank the engine If the engine starts and remains running only as long as the connector is connected the PCM is 3 damaged and must be replaced 3 Engine cuts out on hard Check the secondary fuel injector 3 throttle but 3 connectors 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 accelerates normally If the connectors are not fully under light throttle 3 locked during reassembly they can 1 be mis positioned when the vacuum 3 3
450. en the Kent Moore and OTC flushers A T OIL COOLER amp LINE FLUSHER TABLE A T OIL COOLER amp LINE FLUSHER TABLE KENT MOORE J 35944 MAZ AAAAAAAAARAAAARAAAARARAARARAAAAAAAARAAAARAARARAAAARAAAAAAAAAAAAAAAAA Advantages 3 Disadvantages AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAAAAAAAAAAAABARARAAAA Inexpensive Not as easy to use Requires little storage space Requires shop water and air hoses for flushing procedure Does not require periodic filter replacement Does not recycle its flushing fluid Each flushing procedure quires the disposal of 18 20 al of waste water ATF flushing uid that cannot be dumped in shop drain HOW Dealer must consult state and local authorities for proper disposal of waste AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU w w UQ QU WU w w w ww G G w 3 3 3 3 3 3 3 3 3 3 3 3 3 3 RECOMMENDED A T COOLER LINE FLUSHING EQUIPMENT CAT ST NO 009 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM OTC 60081 M PORTABLE OIL COOLER TORQUE CONVERTER CLEANER OTC 60081 M PORTABLE OIL COOLER TORQUE CONVERTER CLEANER UAAAKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAABAAAAAAAAAAAAAAAAAAAAAAAAAAAAL 3 Advantages I Disadvantages AAAAAAAAAAAA
451. ent inside the hose and there is no sign of breakage remove the oil It is not necessary to replace the hose If the hose is broken replace the hose with a new part and tighten to the specified torque Tf the hose is loose coming off insert properly and tighten to Specified torque NOTE The fuel connector bolt torque should be adjusted to 240 360 kgs cm 208 312 in lbs CAUTION Do not allow foreign material to enter related parts when replacing or reinstalling intake system parts SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM 3 Compression Measurement 4 Turbocharger Operation Controls Inspection TURBOCHARGER OPERATION CONTROLS INSPECTION TABLE UAAAKAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAL 3 Part Name 3 Inspection 3 Procedure 3 3 Item 3 3 3 Check Valve A 3 Reverse Flow After checking the check 3 3 and B 3 valve confirm that air 3 3 hoses C D E F are 3 3 connected See Fig 2 3 RAARARAAAARARAARARAAAARARAARARAARARARARARARARARAARARARRARARAAAA Turbo Control Improper
452. er Normal Warranty Refer To The SRT Microfiche For Warranty Term Information Warranty Type A Symptom Code 30 Damage Code 9H Part Number Main Cause 5555 FE 001 Quantity 0 Operation Number XX0640RX Labor Hrs 0 5 Hrs END OF ARTICLE STEERING WHEEL SLIGHTLY OFF CENTER CANADIAN CAT N NO 95 04 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 24AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN STEERING WHEEL SLIGHTLY OFF CENTER Model 5 1983 95 Mazda Models Except B Series Canadian Category N Steering Bulletin No 95 04 Date April 1995 DESCRIPTION The steering wheel on some models may be slightly off center The vehicle still drives straight and does not pull right or left If a customer complains of the position of the steering wheel confirm that the vehicle is not pulling and repair according to the instructions in this bulletin REPAIR PROCEDURE 1 Drive on a straight road and place the steering wheel in a neutral position If the steering wheel is not centered go to step 2 2 Using the outside circumference of the steering wheel measure th distance between the neutral position and the center position NOTE If the distance is larger than 30 mm 1 18 in remove the steering wheel and reinstall in the correct position If the steering wheel is still of
453. er facia the lock to the right or left until the Ls 94F58797 Fig 1 Hood Lock Adjustment 2 Correct the angle of the hood release knob bracket Adjust the bracket angle to 90 degrees If this angle is not at 90 degrees the release cable may not pull out fully and therefore may not release the lock See Fig 2 HOOD RELEASE INOPERATIVE DIFFICULT TO OPEN REPAIR MT 0295 05 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 37AM Check angle here Incorrect angle shown 94G58798 Fig 2 Hood Release Knob Bracket END OF ARTICLE INSTALLATION OF TIE DOWN HOLE PLUGS AT PDI CAT S NO 050 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 38AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN INSTALLATION OF TIE DOWN HOLE PLUGS AT PDI Model 5 1993 Mazda RX 7 Category S Bulletin No 050 92 Date 10 19 92 DESCRIPTION Tie down hole plugs need to be installed at PDI on vehicles produced after May 20 1992 These tie down holes are used during vehicle transportation The plugs will reinforce anti perforation preventing water and mud from penetrating the body which may result in rust amp Hole Plug 94053985 Tie Down Holes Fig 1 Tie Down Holes The package o
454. er pump 39 Remove the nut attaching the alternator adjusting bracket to the power steering bracket See Fig 26 98151670 Fig 26 Alternator Attaching Nut 0 Remove the water pump and discard Remove and discard gasket and clean gasket surface 41 Install new water pump using the new gasket RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 21 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Instalt New Water Pump And Gasket Clean Surface Prior to Installation 98151671 Fig 27 New Water Pump Installation Note Be sure that oil metering line retaining clip is installed correctly on the outside of the water pump at bolt A See Fig 28 Route Oil Metering Line Properly 98A51672 Fig 28 Oil Metering Line Routing 42 Disconnect the low coolant switch connector See Fig 29 RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 22 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Disconnect Low Coolant Switch Thermostat Cover Thermostat Coolant Level Sensor 98B51673 i Fig 29 Low Coolant Switch Sensor And Thermostat Cover 3 Remove the surge tank hose from the thermostat cover 1 Remove the thermostat cover See Fig 29
455. eratio Rear Brakes Brake Drums s Rear Brakes Brake Drums s Brake Drum s Labor Operati Brake Drum s Labor Operati Brake Shoe s Labor Operati Brake Shoe s R amp R one side n PO201ARX 0 3 hrs R amp R both sides n PO201BRX 0 4 hrs Machin one side on PO201AMX 0 5 hrs Machine both sides on PO201AMX 0 7 hrs R amp R one side on PO204ARX 0 4 hrs R amp R both sides MPV VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Labor Operation 1993 Models on Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC P0204 ly Rear Brakes Brake Drums s Labor Operation Rear Brakes Brake Drums s P0201 Saturday August 25 2001 09 26AM BRX 0 6 hrs R amp R one side ARX 0 3 hrs R amp R both sides Labor Operation PO201BRX 0 6 hrs Brake Drum s Machin one side Labor Operation PO201AMX 0 3 hrs Brake Drum s Machine both sides Labor Operation PO201AMX 0 6 hrs Brake Shoe s R amp R one side Labor Operation PO204ARX 0 5 hrs Brake Shoe s R amp R both sides Labor Operation PO204BRX 0 8 hrs 323 PROTEGE Rear Brakes Brake Drums s R amp R one side Labor Operation PO201ARX 0 3 hrs Rear Brakes Brake Drums s R amp
456. es NOTE The seat belt will not retract smoothly while wet Allow seat belt to dry before verifying operation Dirt Accumulates In This Area Clean Belt With Lukewarm Water Neutral Detergent And Cloth Or Brush Never Use Volatile Solvent 95554912 Fig 1 Dirt Accumulates In This Area END OF ARTICLE DOOR MIRROR VIBRATION APPLY TREAD LOCK TO SCREWS CAT S NO 020 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 35AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN DOOR MIRROR VIBRATION Model s 1993 94 Mazda RX 7 Category S Body Bulletin No 020 95 Date 6 16 95 APPLICABLE MODELS VINS RX 7 model vehicles with a VIN of JM1FD333 R0301491 and lower DESCRIPTION The door mirror may vibrate while driving on bumpy roads This vibration may be caused by loose mirror mounting screws To prevent the screws from loosening a thread locking agent has been added during mass production Customers complaining of this concern should have the vehicle repaired according to this bulletin NOTE Place a copy of this bulletin in your edition of the NVH manual for future referenc REPAIR PROCEDURE 1 Verify the complaint 2 Remove the mirror from the door Refer to section S of the workshop manual for removal instructions NOTE Mirror wiring harness removal is not necessary
457. es Inc 3 3 RTB17200 RTB17500 3 P O Box 8961 3 3 Robinair Division SPX Corp 3 4730 W Bancroft A 3 3 Robinair Way Toledo Ohio 43615 3 Montpelier OH 43543 0193 3 419 531 33X3 3 3 419 485 8300 3 3 Space Age Air Products Inc AES Ntron Models 2 2 and 2 4 3 Model 010 with retrofit kit 3 456 Creamery Way 3 Robinair 17217 3 Exton PA 19341 3 3 I 215 594 9309 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAU TABLE 3 APPROVED RECOVERY ONLY EQUIPMENT TAPTE ER ONT TOUT U 3 3 Manufacturer Model 3 AES NTRON 3 R1 1AC 3 3 Assemblies Systems Corp NS750A no longer manufactured 3
458. ewed from the front or rear The door striker controls the in out location of the door at the rear latch CAUTION DO NOT pry or force the door into alignment In addition to Workshop Manual procedures for door alignment the following information tips are provided As a guideline if the weather strip contact is insufficient the door hinge s should be adjusted 2 4 mm inward Determine the amount of movement by outlining the hinge mount area before door adjustment and after See Fig 3 Adjusting one hinge at a time will prevent any extreme door 3 Fig WIND NOISE AROUND DOORS CAT S NO 018 98 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 44AM movement This is done by loosening the hinge bolts and moving the door with a padded pry bar just enough to permit movement of the door Hinges should be adjusted first followed by the striker Adjustment to the rear door s if applicable may require adjustments to the front door and possibly to the front fender to maintain alignment Door closing effort should be checked to ensure that it remains acceptable after adjustments are completed If any doors are too difficult to close the seal compression may be excessive and adjustment will need to be repeated After completing adjustments verify seal compression by using the card te
459. f center proceed to step 3 3 Measure the distance described in step 2 1f less than 30 mm 1 18 in loosen both left and right tie rod end lock nuts Turn the rods in the opposite directions by the same amount until the steering wheel is centered 4 Road test the vehicle to confirm the steering wheel is centered If not centered repeat step 3 The TIE ROD OUTSIDE CIRCUMFERENCE DISTANCE TABLE below shows the approximate distance that the outside circumference will move per 90 degree turn on the tie rod both left and right in opposite directions TIE ROD CIRCUMFERENCE DISTANCE TABLE s Model F 3 Approx Distance AAAA AAAA AAAA AA AAAA AAAA AAAA AA AAAA ARRAAAAAARARAARA A 3 1990 94 323 Protege With P S 3 8 mm 3 3 STEERING WHEEL SLIGHTLY OFF CENTER CANADIAN CAT N NO 95 04 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 24AM 3 1995 Protege Without P S 3 12 mm 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 4 cyl 3 8 mm 3 3 1992 95 MX 3 h AAAAAAAAAAAARAAAAAAAAAAAAAAA A A 6 cyl 3 7 mm 3 AAAKAAAAAKAAAAAKAAKAAKAAKAAKAAAKAKAAKAAKAAKAAKAAKAAKAAKA 3 1993 95 RX 7 3 Al 3 7 mm 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1
460. f plugs and installation diagram can be found in the vehicle s cargo area The above information is also outlined in the 1993 RX 7 s Service Pr Delivery Inspection PDI Sheet under the Mechanical Preparation Exterior On Hoist procedures END OF ARTICLE KEY CYLINDER REPLACEMENT REKEY CYLINDERS TO MATCH MT 0995 10 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 38AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN KEY CYLINDER Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0995 10 Date 1995 DESCRIPTION If you have to replace a key cylinder door trunk glove box etc don t replace th ntire key cylinder set Most locksmiths can reset the lock tumblers in the new replacement cylinder to match the existing ones Although the factory chrome bezel must be removed and replaced most locksmiths can fit a replacement after market bezel Please contact locksmiths in your area to find one who can provide this service END OF ARTICLE NOISE FROM THE REAR HATCH HINGE REPLACEMENT PARTS CAT S NO 010 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 38AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN NOISE FROM THE REAR HATCH HINGE Model s 1993 Mazda RX 7 Category S Number
461. fan control module See Fig 5 10 Wait for approximately 20 seconds 11 Disconnect cooling fan relay connector A Verify that the cooling fan operates at low speed See Fig 6 COOLING FAN CONTROL MODULE INTERMADIATE i CHECK CONNECTOR 98H51620 Fig 5 Cooling Fan Control Module COOUNG CONNECTOR A FAN RELAY 98151621 Fig 6 Cooling Fan Relay Connector 12 If not inspect the cooling fan relay SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM 13 Connect cooling fan relay connector A Verify that the cooling fan operates at the speed before connector A is disconnected 14 Disconnect the jumper wire from the check connector Verify that the cooling fan operates at low speed 15 Turn the ignition switch to ON 16 Verify that the cooling fan stops 8 12 seconds after the ignition switch is turned to ON 17 If not as specified replace the cooling fan control module COOLING FAN CONTROL MODULE 1993 RX 7 REMOVAL INSTALLATION 1 Remove the ECM 2 Disconnect the cooling fan control module connector 3 Loosen nut A as shown See Fig 7 4 Remove the cooling fan control module 5 Install in the reverse order of removal Tighten Nut A Torque to 7 9 10 7 N m 80
462. fications during production and technicians should also use median specifications during alignment adjustment NEW SPECIFICATIONS TABLE 3 3 Items 3 Standard 3 Note 3 3 Tolerance 3 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Camber Difference 3 R1 5 3 3 3 between right and left 3 degrees 3 3 F 3 Caster Difference 3 R1 5 3 3 3 O 3 between right and left 3 degrees 3 3 N Toe Total toe in 3 hdmm Angle 3 One side is 3 3 3 3 indicated is 3 not mentioned 3 3 3 also described No specification 3 3 3 Camber Difference 3 Al RA1 5 3 3 5 3 between right and left degrees 3 3 R AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAA 3 amp 3 Toe Total toe in s 4mm Angle 3 One side toe is 3 ALIGNMENT SPECIFI
463. flected in DMS tapes will be updated the first week of the Dealer Price List will contain the new Current Pricing 3 Revised Pricing ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 1 000 00 1 000 00 1 250 00 3 3 3 3 1 600 00 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1 600 00 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1 850 00 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 1 250 00 3 3 1 850 00 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 A008 99 008R 3 1970 73 ARAAAAAARAAAAAAAAAAA 3 B008 99 0088 3 1974 78 AAAAAAKAAAAAAAARAAAA 3 C008 99 008R 3 1979 85 3 3 RX 7 12A 3 D008 99 008R 3 1984 85 3 3 RX 7 13B 3 E008 99 008R 86 88 RX 7 13B 3 3 W O TURBO AA 3 F008 99 008R 87 88 RX 7 13B 3 3 W TURBO G008 99 008R 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 89 91 RX 7 W O TURBO 3B 3 3 3 3 3 3 1 250 00 1 250 00 1 250 00 3 3 3 3 3 3 1 850 00 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 1 850 00 3 3 1 850 00 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 H008 99 008R 3 3 3 89 91 RX 7 W TURBO 3B 3 3 1 270 00 3 3
464. formation Company LLC Saturday August 25 2001 07 25AM UAAAKAAAAAAAAAAAAAAAAAAAAAAAAABAAAABAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAL 3 Service Code No 55 3 Pulse Generator AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Step Inspection Action 3 AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1 3 Are there any poor Yes Repair or Replace connector 3 3 connections at pulse 3 s 3 generator and EC AT 3 3 control unit connector or No Go to next step 2 3 3 terminal 3 3 AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 2 3 Connect a circuit tester 3 Yes Go to Step 5 3 3 3 to terminals 2E and 2L as 3 3 3 shown in Fig 6 3 3 3 3 Is input voltage of pulse 3 3 generator at EC AT control A A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 unit OK 3 No 3 Go to next step 3 Acceptable Voltages 3 3 Approx above 0 5 while E 3 3 3 driving above 16 mph 3 3 3 3 3 Approx 0 Vehicle stopped ARAAAAAAAAAAAAAAAARARAAAARAAAARARAAAAAARAAAAAAAAAAAAAAAARAAAARARAARAA 3 3 3 Disconnect 20 pin EC AT 3 Yes Go to next step 3 3 control unit connector 3 3 3 3 3 Is resistance between 2E 3 3 3 3 3 terminal and 2L terminal AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 OK 3 No Go to next step 3 3 3 Resistance 2
465. ful not to damage the pipe at the hose insertion location on the primary inlet side 94D59330 Fig 51 Removal of Hose from Primary Fuel Distributor 26 Install the modified fuel hose on the primary fuel distributor outlet side See Fig 52 NOTE GI When installing do not twist the O ring Replace the bolts with modified ones S letter G in Fig 92 Tightening Torque 25 36 kgf cm 22 31 in lbf Fuel Hose N3Z1 13 420 Bolt 99796 0810 x 2 pcs O ring Bolt i An 94E59331 Fig 52 Primary Fuel Distributor Outlet Modified Hose 27 1 Install the hose on the inlet side of the primary fuel distributor See Fig 53 Submerge the hos nd with the white mark into adhesive Use adhesive specially prepared for this work RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 37 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM NOTE Be careful not to use another adhesive Install the hose white mark side within five minutes after applying adhesive NOTE Before installing the hose degrease the pipe for better adhesion Fuel Hose N32Z1 13 415 94F59332 Fig 53 Installing Hose on Inlet Side of Primary Fuel Distributor Submerging H
466. g criteria have been met RECEIVER DRIER REPLACEMENT CRITERIA Replace the receiver drier when the A C system has been ruptured and all system pressure is lost Receiver drier will require replacement if the compressor oil becomes discolored or foreign substances become visible Refer to the flow chart in this article NOTE Refer to section U of the workshop manual for additional receiver drier diagnostic procedures If an A C component has failed extract the compressor oil from the failed part and inspect the oil according to the procedure described in the following flow chart Follow the procedure to determine if the receiver drier requires replacement as a precaution AAAAAAAAAAAAAAAAAAAAAAAAAR 3 1 Inspect Oil for I 3 Discoloration 3 A AAAAAAAAAAAAAAAAAAAAAAAAU 3 UAAAAAAAAAAAAAAAA Dark Gray or AAA gt AA Replace 3 3 3 Black 3 3 Receiver Drier 3 AAAAAAAAAAAAAAAU AAAAAAAAAAAAAAAAAU AAAAAAAAAAAA AAAAAAAAAAAAR RECEIVER DRIER REPLACEMENT CRITERIA CANADIAN CAT U NO 95 02 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 08AM Golden Brown Light 3 3 Brown Transparent or 3 Yellowish Gray 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 UAAAAAAAAAAAAA
467. gine coolant temperature sensor mal n n PO 210660 A Cop Cooling fan Cooling fan eration relay No 1 relay No 2 Cooling fan Cooling fan Cooling fan relay No 3 relay No 4 operation OFF OFF OFF Engine cool ant tempera ture over 108 C 226 F after ignition switch is tumed OFF Engme cool _ ant tempera ture becomes lower than 108 C 226 F after igni tion switch is tumed OFF to OFF If the cooling fan will From VIN JM1 FD331 PO 210661 and verify that the cooling fan operates approximate he ignition switch is turned to ON n operates tor by using a jumper wire ON ON 1769 F to ON for 15 seconds or longer Turn the ignition switch to ON and Wait for approximately 150 Turn the ignition switch to ON 00 150 seconds not operate inspect the Battery positive voltage Fan control signal Engine coolant temperature signal Ground y o1 owing SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM 7 Turn the ignition switch to OFF 8 Verify that the cooling fan keeps operating after the ignition switch is turned to OFF 9 If not replace the cooling
468. h JMIFD331 P0210623 Category S Body Bulletin No 033 93 Date 7 2 93 DESCRIPTION On some vehicles the passenger door grip may break or become loose This is due to the constant pulling force when closing the door The material used to manufacture the door grip has been improved to reduce the possibility of breakage Passenger Door Assist Grip 946953153 Fig 1 Door Grip REPAIR PROCEDURE If the above condition occurs replace the door grip with a modified part Refer to the appropriate service information for removal and installation procedures PARTS INFORMATION TABLE AAAARAAAARAAAARAAAARAAAARARAAAAAAAAAAARARAAAARAAAARAAAAAAAAAAAAAAAAA Part Number 3 Description Oty Tre 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Code 3 3 New 3 Old 3 3 3 3 3 FDO1 69 44XB 00 FDO1 69 44XA 00 Passenger Door 3 1 A i 1 3 Assist Grip 1 3 3 BROKEN PASSENGER SIDE DOOR GRIP REPLACE GRIP CAT S NO 033 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mi
469. has been modified to reduce the istance between the glass and glass channel This n makes the glass fit flush against the glass channel installation procedures can be found in the appropriate ormation Fig 1 Do Glass Channel EXCESSIVE CLEARANCE Glass 94653062 or Window Illustration WIND NOISE FROM THE DOOR WINDOW NEW GLASS GLIDES CAT S NO 002 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 44AM Front Glass Guide Replace w modified part FRONT 94H53063 Fig 2 Front Glass Guide Replacement PARTS INFORMATION TABLE Part Number 3 Description 3 Qty 2 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 New 3 Old 3 3 3 3 3 58 6018 3 58 601A 7 Front Glass Guide R 3 A 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 FDO1 59 601B 3 59 601A Front Glass Guide L 7 A 3 Er ye
470. he clip claw sideways Dashboard side A g 8574 13 157 Fig 26 Connecting Hose Fuel Distributor amp Vacuum Pipe Assembly Place the Clip Claws in Opposite Directions RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 20 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM 32 3 Replace the main fuel hose with a new one S Fig 27 NOTE The hose and the clips shown in Fig 27 should be replaced with new ones Be careful not to use the hose and the clips other than those included part numbers below Apply adhesive to the hose end short he arrow in Fig 27 then install i adhesive s step 27 1 end side only shown by To apply ct Insertion depth of both hose ends should be 25 30 mm Fuel hose N371 13 421 Clip 8574 13 157 x 2 pcs Clip with Pink colored holder Short end 94F59340 Fig 27 Replacement of Main Fuel Hose 33 Check for fuel leakage WARNING Do not smoke carry lighted tobacco or an open flame of any type when working on or near a fuel related component Highly flammable mixtures are present and may be ignited resulting in possible injury 1 Connect the negative terminal to the battery 2 Connect the fuel pump terminal of the diagnostic connector to RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Ar
471. hell Repair Information Company LLC Saturday August 25 2001 06 56AM CCR ie TERRE 94159326 Fig 44 Four Nuts Holding the Ignition Coil Assembly 22 ACV Removal 1 Disconnect the couplers from each solenoid valve in the ACV 2 Remove the relief air hose S letter E in Fig 45 3 Remove the ACV Re tightening torque of the nuts Tightening Torque 70 100 kgf cm 61 86 in lbf 1 Remove the vacuum tubes from the inlet manifold See Fig 45 Replace the vacuum tubes with new ones Vacuum tube 99351 04095 x 4 pos NOTE When reassembling replace the ACV gasket with a new one Gasket N3A3 13 996 When reassembling be sure to insert the check valve in the step cut position of the intake manifold then attach the ACV Make sure that the wire harnesses of the solenoid valve will not touch the ACV RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 32 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 94159327 Fig 45 Removal of Relief Air Hose amp Vacuum Tubes 23 Move the vacuum pipe assembly toward the steering shaft side See Fig 46 1 Loosen the thr bolts that attach the vacuum pipe to the ngine S letter C in Fig 46 2 Disconnect the coupler from the solenoid valve attached to the vacuum pipe
472. hreads of any old residue Be sure to clean out the female portion as well using a wire brush brake cleaner and an air hose When parts are dry apply 3 4 drops of Loctite Threadlocking Adhesive Sealant 272 Loctite part number 27200 on the male threads one full thread back from the lead thread Assemble and torque to specification in less than 5 8 minutes END OF ARTICLE BRAKE DRUM ROTOR RESURFACING MACHINERY SELECTION MT 0897 06 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 24AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER BRAKE DRUM ROTOR RESURFACING Model 5 Category Bulletin No Date DESCRIPTION Although some drums for condi All Mazda Models Mazda Tips MT 0897 06 August 1997 workshop manuals may recommend sanding rotors and tions such as minor scoring glazing or surface irregularities To repair the used to machine it is not an acceptable repair method se conditions an on the vehicle brake lathe should be rotors and a standard lathe used for drums Note If a customer complains of occasional brake noise sanding or machini ng alone will not be a permanent repair and will result in a customer comeback likely END OF ARTICLE BRAKE JUDDER REPAIR CANADIAN CAT P NO 94 06 Article Text 1
473. ift A 3 3 ground and terminal B of 3 3 Tf OK go to next step 3 E 3 solenoid valve shift A 3 If not OK repair wiring 3 3 OK 3 3 and or connector 3 Resistance 20 40 ohms AAAAAAAAAARAAAAAAAAARAAAARAAAAAAAAN 3 3 3 No Replace solenoid valve 3 3 3 3 shift A 3 AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 5 3 Disconnect negative 3 Yes Replace EC AT control unit 3 3 battery cable for at least 3 3 3 20 seconds 3 3 Connect battery cable and No Intermittent poor connection 3 3 recheck for service cod 3 3 Check for cause 3 3 Is service code displayed 3 3 U WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 16 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 26AM EC AT CONTROL UNIT 94G55430 Fig 10 Service Code 60 Circuit Diagram SERVICE CODE 61 DIAGNOSTIC TABLE AAAAARARAARARARAAAAAARAAAARARAARAAAARARAAAAAAAAAAAAARAAAARAAAAAAAARA 3 Service Code No 61 3 Solenoid valve Shift B AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
474. ig E ri Aci 3 Bi Jd Axim iH Z es V gerer sS Moms an x T D a cm 95151951 1991 94 Navajo O Ring Identification 19 Fig END OF ARTICLE A C O RING REPLACEMENT GUIDE CAT U NO 001 94 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN A C O RING REPLACEMENT Model 5 All Mazda Vehicles Category U Bulletin No 001 94 Date 2 28 94 Revised 4 28 94 DESCRIPTION Refer to the following illustrations and O RING INFORMATION TABLE when replacing air conditioning system o rings These o rings are designed for use in both R12 and R134 air conditioning systems O RING INFORMATION TABLE UAAAAAAAAAAARAAAAAAAABAAAAAAAAAAAAAAAAAAAAAAAAABAAAABAAAAAAAAAAAAAAAAAL 3 O Ring Description AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 O Ring 3 A3 B 3 Gr 23 Dit 3 E 3 F 3 G 3 Hy 3 J 3 K gt 3 Code 3 3 3 3 3 3 3 3 3 3 RAARRAARAARRAAAAARAARAAARAAARARAAARAARAAARAAAAARAAAAAARAAARAAAAARAAAR 3 Pipe 6mm 5 16 3 8 12mm 12mm 16mm 16mm 3 3 3 3 3 Size 3 3 AY v 3 axial 3 axial 3 3 O Ring 6 9x 6 8x 7 6539 10 839 10 8339 14 0380 13 4x3 3 8 1 2 5 8 3 Size 1 78 31 5 31 78 21 78 22 4 31 78 2 4 3 3 3 3 D x T 3 3 3 3 3 3 3 3 3 3 3 AAMAAAAAAAAAAAAAAAAAAAAAAAA
475. ight 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 40AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN TURBO CHARGER BOLT SET Model 5 1993 94 Mazda RX 7 Category Mazda Tips Bulletin No MT 06 13 Date 1995 DESCRIPTION A bolt set is now available for the turbo chargers The part number is N3A1 13 Z2L7 See Fig 1 Turbo charger boits Fig 1 Turbo Charger Bolt Location END OF ARTICLE UNUSUAL NOISE FROM THE RIGHT ENGINE MOUNT CAT B NO 002 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 40AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN UNUSUAL NOISE FROM THE RIGHT ENGINE MOUNT Model 5 1993 Mazda RX 7 with a VIN of JMIFD3 P0207061 or lower produced through May 31 1992 Category B Engine Bulletin No 002 93 Date 2 26 93 DESCRIPTION On some vehicles an unusual noise may be heard from the right engine mount This noise is most evident during idle or when driving on rough roads and or speed bumps See Fig 1 FRONT Engine Mount R Replace w modified part E 94E52765 Fig 1 Motor Engine Mount Illustration REPATR PROCEDURE If the above condition occurs replace the right engine mount with a modified part The clearance between the rubber mount and mount housi
476. ilar to CaRFG for a number of years However considerable testing indicates that older high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasoline NOTE Owners of older vehicles ar ncouraged to have their vehicle s fuel systems inspected periodically and to follow their vehicl manufacturers recommendations regarding vehicle maintenance CALIFORNIA REFORMULATED GASOLINE CAT F NO 014 96 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM ODOR EMITTED FROM CaRFG CaRFG is not expected to smell different from gasoline most vehicles currently use If unusual odor is noticed it is probably be from oxygenates Most service stations use vapor recovery systems to minimize gasoline vapor release to the atmosphere during refueling ADDITIONAL INFORMATION REGARDING CaRFG Customers can receive more information on CaRFG from the California Air Resources Board at the following toll free number 1 800 922 7349 END OF ARTICLE ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM ARTICLE BEGINNING TE
477. in Fig 15 makes the work easier NOTE Do not remove hoses other than 1 14 Remove the hoses on the sides indicated by arrows shown in Fig 15 Be careful not to damage any pipes When removing the hoses do not use any spray type lubricant 4 Move the vacuum pipe assembly toward direction D as shown rn Eug 5 5 When reassembling replace the hoses 1 2 3 4 5 6 7 8 10 and 11 with new ones RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM P RY S RY NS Fuel QE REP of a ia Fuel pipe main Cm step 32 2 Ww m d lt a NOD S ou SO cf n 94559328 Fig 15 Exploded View of Tubes amp Hoses for Modification 24 Removal of primary fuel distributor secondary fuel distributor and insulator See Fig 16 1 Loosen the four bolts 2 Loosen the connector bolt from the inlet of the secondary fuel distributor Bolt Fuel Connector 94A59329 Fig 16 Removal of Primary amp Secondary Fuel Distributor amp Insulator RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company
478. ine Pressure psi __Kg cm2 3 so ile 7 Stall 7 3 P 3 3 N A 3 AAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAA 3 R 3 3 3 AAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAA 3 R 3 3 3 AU Other findings from diagnosis Fax this sheet to M A S H 714 442 6598 prior to requesting authorization for replacement A copy of this diagnostic sheet and the R O must be attached to the old A T unit when returning it to Mazda M A S H phone number 800 832 4940 AUTOMATIC TRANSMISSION DIAGNOSTIC SHEET LA4A EL amp A4LD P amp A Code R O DATE Model Year VIN Mileage No Tenths 2 CUSTOMER CONCERN Shifting Engagements Does Not Occur Slips Delayed Harsh A Engagements into Drive HE s EM B Engagements into Reverse A
479. ion Company LLC Saturday August 25 2001 09 38AM NOTE Do not remove the vacuum tube from the solenoid Tightening Torque 70 100 kgf cm 61 86 in lbf 94F59324 Fig 42 Three Way Solenoid Nut to be Removed 20 Remove the oil filler pipe See Fig 43 Tightening Torque 70 100 kgf cm 61 86 in lbf 4 ww Y W 94G59325 Fig 43 Oil Filler Pipe Identification 21 Remove the ignition coil assembly Remove the four nuts shown in Fig 44 Tightening torque of the nuts for reassembly Tightening torque 70 100 kgf cm 61 86 in lbf RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Fig 22 Le 2 44 Article Text p 31 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM MOVE ASA h Le 2 of 94H59326 qi Four Nuts Holding the Ignition Coil Assembly ACV Removal Disconnect the couplers from each solenoid valve n t S letter E Remov relief air hos in Fig he ACV Re t ng Torque Remove t Tighteni 70 100 kgf cm 61 86 in lbf Remove the vacuum tubes from the inlet mani NOTE fold Replace the vacuum tubes with new ones Vacuum tube 99351 04095 x 4 pos When reassembling replace the ACV gasket with Gasket N3A3 13 996 be sure to insert th
480. ion Company LLC Sunday August 19 2001 01 47PM Reimbursement is based on Dealer Net Price DNP plus 30 on 1993 and earlier models and DNP plus 40 on 1994 and later models REPLACEMENT BATTERY WET BATTERY Covered for the first 12 months and a Pro Rated warranty applies from 13 months to 36 months Reimbursement for Labor Labor charges related to warrantable repairs on replacement batteries are fully covered up to 12 months Labor is not covered on replacement batteries replaced under the 13 to 36 month pro rate The customer s responsibility is the Pro rate amount based on the retail price of the replacement battery Warranty claims must be submitted with warranty type code P Parts Warranty or K Over the Counter for proper processing Battery warranty start date on the Replacement battery begins on the installed date The warranty coverage starts over on the date of each battery installation Over The Counter battery warranty starts on purchase dat Th customer is responsible for labor charges if any Warranty is only applicable to Mazda vehicles Replacement Miata batteries are covered under the Replacement Battery warranty Replacement Batteries which fail within 12 months Interstate will provide the dealer a new battery at no cost If the dealer should submit a Enter X5555 This will reimburse installs the warranty battery
481. ior to replacing an automatic transmission assembly Transmissions replaced without prior authorization will not be considered for warranty reimbursement REPAIR PROCESS OVERVIEW 1 Record the customer concern and the conditions when the concern exists Validate by duplicating the customers concern If the concern cannot be duplicated check M Tips On for service information If no MTO information exists the vehicle to the customer with an explanation of yo Line ret ur al to duplicate the concern Request the customer demons condition to service management MTO turn ttempts trate the NOTE IMPORTANT NOTE I g AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM If a concern exists Determine th TRANSMISSION APPLICATION CHART Perform the diagnosis DIAGNOSTIC FLOW CHART and record the data transmission type using the AUTOMATIC as described in the AUTOMATIC TRANSMISSION A available sheets B Warranty c The Automatic Transmission Diagnostic Shee from Helm The part number for the pad is 9999 95 TRANS 95 ts ATDS are in pad form Each pad contains 100 TC laims submitted for A T Performance Tests must have a copy of the AUTOMATIC TRANS
482. ir Intake Pipe Cover Outlet With Shop Towel 94F59316 Fig 3 Disconnecting the Air Pipe 10 Disconnect the AWS hose and Air Duct B at the joint as shown RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM In SEL 3 11 Remove the air intake pipe from the outlet of the turbo and cover the outlet with a shop towel 12 Remove the air duct from the inter cooler 13 Remove the hoses from the extension manifold See Fig 4 NOTE Disconnect the hoses at the locations indicated by arrows only Remove these four parts referring to Step 16 Pressure Sensor PCV Hose 1 Double Throttle Control Hose 2 Purge Control Hose 3 Vacuum Chamber Hose ACV Nacuum Hose EGR Vacuum Hose 94G59317 Fig 4 Removing Hoses amp Harnesses From the Extension Manifold NOTE Use the above illustration to determine the hose location RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 14 Remove the harnesses from the extension manifold See Fig 4 15 Remove the accelerator cable and the cruise
483. ition switch to ON 16 Verify that the cooling fan stops 8 12 seconds after the ignition switch is turned to ON 17 If not as specified replace the cooling fan control module COOLING FAN CONTROL MODULE 1994 RX 7 REMOVAL INSTALLATION 1 Remove the ECM 2 Disconnect the cooling fan control module connector 3 Loosen nut A as shown See Fig 7 4 Remove the cooling fan control module 5 Install in the reverse order of removal Tighten Nut A Torque to 7 9 10 7 N m 80 110 kgs cm 70 95 in lbs INSPECTION 1 With the cooling fan control module connector connected measur the voltage at each terminal of the connector Using a voltmeter ground the negative lead to the body and insert the positive lead in each terminal of the connector 2 If there is any incorrect output voltage while all input voltages are correct inspect related systems See Figs 8 thru 10 When the Systems are normal replace the cooling fan control module SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 20 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM COOLING FAN RELAY NO 1 2 3 4 1994 RX 7 INSPECTION 1 Disconnect the cooling fan relay 2 Apply battery positive voltage and ground to terminals A and B of the cooling fan relay See Fig 11 3
484. justed to the left towards increments until the desired temperature is reac d temperature the the cold setting by hed HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Type A Cold gt Hot Type B ijn cu Ha 94C50593 Fig 7 Temperature Selector Type and B Climate Control System Shown in Fig 8 is a typical climate control system Detailed descriptions of each function are found under the heading Driving Your Mazda in the appropriate Owners Manual Type A Temperature lever Air intake selector Side vent Vent Side vent Fan switch Air conditioner Type B Function selector switch Air intake selector Lap louver Lap louver Climate control panel Air conditioner switch 94D50594 Temperature lever Fan switch Fig 8 Climate Control System Layout END OF ARTICLE HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN REQUIREMENTS OF HFC 134A A C RECOVERY AND RECYCLING TRAINING amp EQUIPMENT Model 5 All Mazda Models Category ST Special Tools Bulletin No 008 95 Da
485. l 3 degrees 25 to 5 degrees 25 3 3 NOTE Specifications may differ between models i U 3 Follow the operating procedures specified for the alignment equipment being used 4 Prior to measuring the current settings firmly push the vehicle bumper up and down to stabilize the vehicle s height ALIGNMENT SPECIFICATIONS AND TOLERANCES INFORMATION CAT N NO 001 95 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 22AM END OF ARTICLE CHECKING PROCEDURE FOR POWER STEERING BOOT LEAKAGE CAT N NO 004 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 23AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN CHECKING PROCEDURE FOR POWER STEERING BOOT LEAKAGE Model s All Mazda Models with Rack Pinion Category N Steering System Bulletin No 004 97 Date December 28 1997 DESCRIPTION Customers complaining of problems associated with power steering fluid loss should have the vehicle inspected according to the instructions in section N of
486. l Repair Information Company LLC Saturday August 25 2001 09 40AM 3 3 Light ON Light OFF 3 3 Clutch 3 Pedal 3 Pedal 3 In neutral Q 3 switch MT depressed released 3 3 3 Neutral 3 In gear 3 Neutral 3 Clutch pedal released 3 3 switch MT 3 3 3 3 3 Inhibitor qus D E N or P 3 3 3 switch AT or R range range 2 3 3 Headlight ON 2 OFF 3 Headlight switch 3 switch 5 3 3 I or II position 2 3 Blower 3 ON 3 OFF 3 At 3rd or 4th position 3 switch 3 3
487. l balance than usual Use the proper size cone on the inside of the wheel for precise center hole positioning on the spindle If the cone diameter and wheel hole are not properly matched it may cause too much run out and incorrect wheel balance For improved centering tighten the wing nut while turning the wheel by hand Adjust the unbalance amount to the smallest possible 10 grams or 0 35 ounces or less Most wheel balance machines do not indicate heck the precision o o Q unbalance amounts of less than 10 grams operating instructions for it s accuracy specification so check your machine s your balancing equipment and procedure hen you are finished with the wheel balance turn the wheel pproximately 90 degrees on the balancer and check again If the nbalance amount is greater than 10 grams there is a problem with ither th quipment or the balancing procedure END OF ARTICLE WHEEL CENTER CAP STICKS OUT MODIFIED CENTER CAPS CAT Q NO 003 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 26AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WHEEL CENTER CAP STICKS OUT Model 5 1993 Mazda RX 7 Category Q Number 003 92 Date 9 14 92 DESCRIPTION Some vehicles may have aluminum wheel center cap s that do not fit flush
488. l lully depressed Throne Actele sior pedal released CLR e ignition switch Consent sensor lui PT ON Accierator peop luy depressed 42 2464 S Alia esr ug 0 Thwoltle opening above 1 6 Engine coot ani Wemp below 40 C 104 F _ _ Engine speed 1500 3 300 pm 5 70 Reference Wre running z _ comen 4 Ignition swich ON Trrowie Constant Approx 50V Nikon switch ON kie Temp Below 100 C 212 F Sensor on onm C EGR twitch E valve operales aklornia on Me Ten pui EGR valve doss nol operaie OFF Engine speed DRL relay r Puil Ina parking brake OFF Canada only Kjte baiow 3 750 rpm Turniight OFF Engine speed Release ine parking brake on _ above 3750 pm Turnignt ON O Solenmd vaive ignition switch ON dle Beior warm up approx ON AGE ner Ie Alter warm up OFF 94B54057 Fig 2 Wiring diagram Revision Page 40 END OF ARTICLE YEAR 2000 COMPLIANCE CAT 01 NO 018 99 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 48PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN YEAR 2000 COMPLIANCE Model 5 All Mazda Models Category 01 Engine Bulletin No 018 99 Date May 28 1999 DESCRIPTION Because all Control Units including the Powertrain Control Mod
489. l pressure gauge on the outlet side of the fuel filter See Fig 6 for illustration 94453033 Fig 6 Checking Fuel Pressur 6 Short circuit the fuel pump test terminals yellow 2 pin connector with a jumper wire on the following vehicles s Fig 7 1988 89 323 1993 626 MX 6 1990 91 929 1989 92 MPV 1989 91 RX 7 7 Short circuit the fuel pump check terminal and the ground terminal of the diagnostic connector with a jumper wire on the following vehicles s Fig 7 1990 93 323 Protege 1993 626 MX 6 1992 93 929 1992 93 MX 3 1990 93 MX 5 1993 RX 7 ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM 94B53034 Fig 7 Short Circuiting Fuel Pump 8 Turn the ignition switch on and measure the maximum fuel pressur Turn the ignition switch off and remove the jumper wires See FUEL PRESSURE TABLE For standard values FUEL PRESSURE TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Year Model 3 Standard Value PSI 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAAAA 3 1988 89 323 3 49 or Over 3 3 1990 91 323 Protege 3 3 3 1990 92 626 MX 6 3 E 3 1990 91 929 3 3 3 MPV All 3 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAAAA 3 1992 93 323 Protege 3 52
490. le Warranty Towing is not covered under the replacement battery warranty or any other applicable warranty unless the vehicle falls under the New Vehicle Limited Warranty MILEAGE ALLOWANCE Battery warranties are based on Time months and are not limited by mileage considerations BATTERY CHECK SHEET A Battery Check Sheet must be completed and retained with repair order for any battery replacement under warranty EMERGENCY REPLACEMENT Reimbursement for battery emergency replacement must reflect applicable pro rate Refer to Emergency Repairs in the Resources section for more information Note All emergency battery replacements require DCSM authorization WARRANTY CONDITIONS Unless specified all warranty coverage and application limitations apply to battery warranty repairs as referenced in the vehicle s Warranty Information booklet All batteries are covered for defects in material and workmanship Coverage does not extend to batteries that have been improperly stored or that show sign of Abuse Improper handling Lack of proper maintenance DCSM AUTHORIZATION Battery replacement for vehicles in dealer inventory and during the first 90 days following retail sale requires DCSM authorization STORAGE All batteries must be properly tagged and held for inspection and core credit WARRANTY BULLETIN MAZDA BATTERY WARRANTY CAT G NO 1 Article Text
491. lers leakage coolant system components potentia will inspect the vehic or if the coolant level Melted lly subject to deterioration level is set too This can cause the coolant to reach temperatures that exceed the design limits of some components of the coolant system engine coolant can Should leak collect on top of the engine ngine coolant leaks onto the hot engine exhaust manifold from the an engine compartment fire can result les and if any vehicle exhibits coolant has dropped to the point where the loss would be sufficient to trigger the coolant warning from overheating would be replaced These parts include the water pump bearing housing the wat thermostat gasket addition all vehicles also have the cooling system and other systems that carry flammabl liquids checked to make certain that any problems in those systems repaired The radiator cap recalled vehicles will NOTE ngin filler cap be replaced by newly designed parts r level sensor and radiator upper hose the and all water hoses located above th ngin In in which those components are replaced would e overheating had not caused any identified problems will be and filler cap body of al RADIATOR CAP PRESSURE SET TOO HIGH Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday
492. les 1 Start the engine 2 Remove the circuit opening relay See Fig 1 age E S A lt ein b LE 34D69314 Circuit a Relay Fig 1 Location of Circuit Opening Relay 3 After th ngine stalls crank the engine for 15 20 seconds to purge the injectors 4 Turn the ignition switch off 5 Install the circuit opening relay 6 Disconnect the negative terminal from the battery NOTE Record all preset stations on the vehicle s audio system prior to disconnecting the battery terminal 7 Drain coolant and retain in an appropriate container RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM 8 Remove the bolts from the duty solenoid and the pressure chamber See Fig 2 Tightening Torque 70 100 kgf cm 61 86 in lbf Duty Solenoid Remove Bolts from Duty Solenoid 94E59315 Fig 2 Removing Bolts from Duty Solenoid 9 Disconnect the air pipe at joint A shown in Fig 3 Air Intake Pipe Cover Outlet With Shop Towel 94F59316 Fig 3 Disconnecting the Air Pipe 10 Disconnect the AWS hose and Air Duct B at the joint as shown RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Satu
493. ling fan keeps operating after the ignition switch is turned to OFF 9 If not replace the cooling fan control module See Fig 5 10 Wait for approximately 20 seconds 11 Disconnect cooling fan relay connector A Verify that the cooling fan operates at low speed See Fig 6 COOLING FAN CONTROL MODULE INTERMADIATE i CHECK CONNECTOR 98H51620 Fig 5 Cooling Fan Control Module COOUNG CONNECTOR A FAN RELAY 98151621 Fig 6 Cooling Fan Relay Connector 12 If not inspect the cooling fan relay SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM 13 Connect cooling fan relay connector A Verify that the cooling fan operates at the speed before connector A is disconnected 14 Disconnect the jumper wire from the check connector Verify that the cooling fan operates at low speed 15 Turn the ignition switch to ON 16 Verify that the cooling fan stops 8 12 seconds after the ignition switch is turned to ON 17 If not as specified replace the cooling fan control module COOLING FAN CONTROL MODULE 1993 RX 7 REMOVAL INSTALLATION 1 Remove the ECM 2 Disconnect the cooling fan control module connector 3 Loosen nut A as shown See Fig 7 4 Remove the cooling fan
494. lip 8574 13 157 x 2 pcs Clip with Pink colored holder Short end 94F59340 Fig 27 Replacement of Main Fuel Hose 33 Check for fuel leakage WARNING Do not smoke carry lighted tobacco or an open flame of any type when working on or near a fuel related component Highly flammable mixtures are present and may be ignited resulting in possible injury 1 Connect the negative terminal to the battery 2 Connect the fuel pump terminal of the diagnostic connector to RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 21 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM the ground terminal See Fig 28 3 Pinch the fuel return hose with a suitable tool to stop any fuel return to the tank See Fig 29 NOTE Use a dull edged SST so that it does not damage the hose 4 Operate the fuel pump for more than five minutes and check for fuel leakage Check for fuel leakage visually and by odor Carefully check the positions seven indicated by the arrows shown in Fig 29 If fuel leakage is found repair the problem Once repaired check again according to the above steps Diagnostic Connector To round Terminal 94G59341 Fig 28 Diagnostic Connector to Ground Terminal RX 7 FUEL LEAKAGE RECALL CAMPAI
495. ll affect PCM control of idle speed Customers complaining of low idle speed should have their vehicl repaired using the Workshop Manual NOTE Tampering with this screw will affect the idle contact switch and or throttle position sensor settings This can lead to rough idle and difficulty in diagnosis of idle quality concerns The TAS locations on the examples below may vary depending on model year of vehicle S Fig 1 TAS THROTTLE ADJUSTMENT SCREW LOCATION ADJUSTMENT CAT F NO 014 98 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 01AM I 98B54057 Fig 1 Throttle Adjustment Screw Locations END OF ARTICLE WORKSHOP MANUAL CORRECTION FUEL SYSTEM INSPECTION CAT W NO 028 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 02AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WORKSHOP MANUAL CORRECTION FUEL SYSTEM Model 5 1986 88 Mazda RX 7 1993 Mazda RX 7 Category W Workshop Manual Corrections Bulletin No 028 92 Date 7 23 92 DESCRIPTION Attached are procedures for the 1986 88 RX 7 Workshop Manuals which provide clear fuel system inspection procedures Also attached are corrections for the 1993 RX 7 Workshop manual AFFECTED PAGE
496. ll air intake pipe bracket See Fig 9 REPLACEMENT OF THE REAR WATER HOSE 23 Remove the following parts O2 Sensor Coupler on the ACV ACV Vacuum Tubes Double Throttle Control Actuator Hose Pressur Regulator Cut Valve Vacuum Hose Rear Secondary Injector Coupler Fuel Return Hose See Figs 11 thru 16 RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 11 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Oo sensor coupler on the ACV 98151655 Fig 11 O2 Sensor Coupler on the ACV DO NOT A ACV vacuum tubes 98A51656 Fig 12 ACV Vacuum Tubes RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM DO NOT DAMAGE HA AA LR N Double throttle control actuator hose x 98B51657 Fig 13 Double Throttle Control Actuator Hose Pressure regulator cut valve vacuum hose 98C51658 Fig 14 Pressure Regulator Cut Valve Vacuum Hose RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Rear secondary injector coupler 98D51659 i Fig 15 Rear Secondary Injector Coupler Fuel return hose on the
497. ll temperatures for A T amp M T 2 Turn off the A C compressor when the clutch pedal is depressed or when the accelerator pedal is released for M T REPAIR PROCEDURE Removal amp installation procedures can be found in the appropriate service information See PARTS INFORMATION TABLE for list of replacement parts PARTS INFORMATION TABLE AAAAARARAARAAAAAAAAAAAAAAARAAAARARAARAAAR 3 Part Number 3 Description ANAARAAAAAAAAAAARARARARAAAARARAAARAARARARA 3 N3A1 18 881R 3 ECU Federal M T 3 ENGINE STALLS DURING DECELLERATION REPLACE ECU CAT F NO 032 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 59AM AKAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAA 3 N3A2 18 881R 3 ECU Federal A T 3 AKAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAA 3 N3A3 18 881R 3 ECU California M T 3 AKAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAA 3 N3A4 18 881R 3 ECU California A T AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU CORE RETURN PROCEDURES 1 Fill out a Warranty Shipping Record form 2 Ship the old ECU to MMA Customer Support 2 Cromwell Irvine CA 92718 ATTN Warranty Dept 3 Failure to ship the old ECU will result in the denial of the warranty claim 4 Refer to Parts Bulletin No R for details WARRANTY INFORMATION Applies to Vehicles Covered Under Warranty
498. lled into vehicle Installation date Part Number Unit Serial No 5 Transmission Identification MCI use only Original unit reman unit Unit Serial Number END OF ARTICLE ALIGNMENT SPECIFICATIONS CANADIAN CAT N NO 95 02 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 22AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ALIGNMENT SPECIFICATIONS Models 1993 95 Mazda Models Except 1994 95 B Series Canada Category N Steering Bulletin No 95 02 Date January 1995 APPLICABLE MODELS All models except 1994 95 B Series DESCRIPTION This bulletin provides background information on standard Specification and measuring conditions for wheel alignment Measured vales are not absolute Variations occur between technician equipment and the condition of the vehicle at the time of measurement To avoid unnecessary adjustments specifications and measurement conditions have been changed in the Workshop Manual These changes are described below NOTE Changes in the specifications do not imply that alignment tolerances have increased during production Vehicle alignment is set to the median speci
499. lling the Catch Tank during reassembly be sure to route the vacuum hose from the purge control and to the catch tank on t i ne he outside of the oil filler Otherwise the vacuum hose could nterfere in proper operation of the throttle linkage The Fan Control System fastener A is a gray plastic phillips screw in fastener Remove and discard the fastener The bolt at the top of the ECU should be loosened to allow the ECU to be slid down and away from the kick panel IL is not necessary to remove the wiring connectors from the ECU to perform this procedure Just move the ECU over toward the center of the passenger area floor SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM DRIVEABILITY TROUBLESHOOTING TIPS Lack of Power Rough idie and Hesitation Start Engine Check each solenoid and actuator operation 2 NOTE A problem may have occured during assembly atter recali repairs were performed i e kinked loose or broken hose Remove Hose A Refer to Fig Beiow Within Specificaton Disconnect the knock sensor coupler Does condition change Call MASH Hotline Check for intake system leakage or air hose loose or not connected Co
500. lti Prep DX103 Optional Available through authorized PPG distribution locations PAINTING PROCEDURE SAMPLE MAZDA Plastic Bumper Cover Refinish System NOTE Products used to refinish flexible bumper covers fall under the category of SPECIALTY COATINGS therefore products specified in the system below may be used in any VOC regulated area UAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAARAARAAAAAAAAAAAAAAAAAAAAARAA Clean with DX 393 0 6 Low VOC Cleaner or DX 394 1 4 Low VOC Cleaner AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA Wipe Down with DX 103 DX 103 MULTI PREP 6 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 0 Abrade Panel with a Gray Abrasive Pad AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 0 Wipe Down with DX 103 MULTI PREP AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 AAAAAA AAAAAAA AAAAAAAA AAAAAAAA 3 A 3 3 B 3 3 3 New Replace
501. m Type B eg e umm 94A50591 Fig 5 Air Intake Selector Type A and B Item 2 Function Selector This selector controls the direction of the airflow from the vents On initial start during cold or high humidity temperatures the selector should be placed in the defrost position and the fan speed set to 3 or 4 After the front and side windows become clear the selector can be switched to defrost heat and then to heat only as necessary and the fan speed reduced If the front or side windows begin to fog again while driving the selector should be reset to the defrost heat or full defrost and the fan speed adjusted as necessary above air conditioning can be used in conjuncti system to control the humidity level in the vehi In addition to the on with the heating heat Type A a 7 A vd 8H C2 Co co ca T 94B50592 Fig 6 Function Selector Type A and B Item 3 Temperature Selector Lever This lever controls air temperature by sliding t temperatures the selector should be set to the f far right of the selectors travel See Fig 7 cle while providing he lever either to the right for hot or to the left for cold On start up during cold ull heat position at As the interior of the vehicle reaches the desir selector should be ad
502. m Schematic RARARARARARARARAAAAAARARARARARARARARAAAAARARARARARARARAAA A gt Item Description Part 1 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM A 3 Check Valve Positive Pressure N390 13 995A 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 B 3 Check Valve Positive Pressure N390 13 995A 3 AR AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 e Vacuum Hos Pressure Chamber N3A1 20 341 3 3 3 Exit 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 D E Vacuum Hos Pressure Chamber N3A1 20 342 E 3 Entrance 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 E i Vacuum Hose Check Valve 3 N350 13 B96 3 3 2 Entrance 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 F 3 Vacuum Hose CCV No 3 3 N3A2 20 362 3 3 s Solenoid 3 3 ARAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAARAA 3 1 If part is removed replacement is necessary 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU COOLING FAN CONTROL SYSTEM 1993 RX 7 DESCRIPTION To improve idle smoothness and engine reliability the cooling fan control syst
503. mage to the gasket If the proper torque tightening sequences is not followed cracks and or breakage may occur INSTALLATION PROCEDURE Refer to the instructions and tightening sequences shown in Fig 1 when installing the gasket Make a note in the applicable workshop manuals to avoid problems during installation INTAKE MANIFOLD GASKET PRECAUTIONS CANADIAN CAT F NO 95 03 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Step 1 Apply molybdenum grease to flange Do Not Apply To Gasket Step 2 Tightening Torque 16 20 Nm 1 6 2 3 kgfm 12 16ft Ibs 94G58863 Saturday August 25 2001 09 35AM RE 4 N Qa N EN N A Na si Bhd Fig 1 Intake Manifold Gasket Tightening Sequences END OF ARTICLE KINKED TURBO CHARGER RELIEF VACUUM HOSE NEW HOSE MT 1195 09 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 35AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN T C VACUUM HOSE Model s 1993 Mazda RX 7 Section Mazda Tips Bulletin No MT 1195 09 Date 1996 SERVICE PROCEDURE A kink in the T C relief valve vacuum hose may cause th ngine to hesitate or lack power during acceleration Check the hose and replace it with a modified one if it is kinked The new part number is available th
504. ment 3 Existing Panel 3 Heavily Damaged Panel oe Minor Repair Repair Tears AAAAAAAAAAAAAAAAU AAAAAAAAAAAAAAAU 3 Punctures etc 3 3 AAAAAAAAAAAAAAAAAAU 3 3 3 3 3 UAAAAAAAAAAAAAAAAAA 3 3 3 DPX 801 3 E 3 3 Universal Plastics B 3 3 AAAAAAAAAAAAAAAAAAAU 3 3 3 3 3 UAAAAAAAAAAAAAAAAAA 3 3 3 Flexible 1 3 7 3 3 Repair Material or Plastic Weld 3 AAAAAAAAAAAAAAAAAAAU 3 3 3 PRE PAINTING PREPARATION FOR FRONT amp REAR BUMPERS CAT S NO 020 97 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 39AM 3 UAAAAAAAAAAAAAAAAAA UAAAAAAAAAAAAAAAAAA 3 3 DPX 801 3 DPX 801 3 3 Universal Plastics 3 Universal Plastics E 3 Primer 3 3 Primer i AAA AO A AU 3 3 3 3 UAAAAAAAAAAAAAAAAAAAA UAAAAAAAAAAAAAAAAA 3 3 Flexibilized K 36 3 3 Flexibilized K 36 3 3 Primer Surfacer 1 3 Primer Surfacer 1 3 i ARARARARARAAAAAAAAAAAU ARAAAAAAAAAARARARARARU 3 3 3 AAAAAAAAAAAAAAAAAA AAAAAAAA AAAAAAAAAA AAAAAAAA AAAAAAAAA DPX 8013 3 3DP Epoxy LF DP 401 3 DP Epoxy LF DP 401 3 Universal Plastics LF 2 1 1 3 3 2 1 1 3 9 Primer 3 Epoxy Sealer 2 3 3 Epoxy Sealer 2 3 AKAAAAAAAAAAAAAAAAAU AAAAAAAAAAAAAAAAAAAU AKAAAAAAAAAAAAAAAAAU 3 3 3 AKA
505. mobile ALTERNATIVE REFRIGERANTS EPA S Significant New Alternatives Policy SNAP program reviews alternatives to CFC 12 to determine the risks posed to human health and the environment by that alternative HFC 134a has been approved under the SNAP program Some refrigerant manufactures and distributors are conducting research to determine if other substitutes exist which will cool adequately work compatibly with the components in A C systems with minimal retrofit procedures These substitutes must be reviewed under the SNAP program It is important to keep in mind that the SNAP program does not evaluated th ffect of a substitute refrigerant on the life or performance of the components in your car s A C system or the effect of a substitute on the system s cooling capacity By November 15 1995 all substitute refrigerants will have to be recovered and recycled technicians handling those substitutes will have to be certified and equipment used to service those substitutes will have to be approved By complying with these regulations you will help preserve the ozone layer for future generations For further information please contact the Stratospheric Ozone Information Hotline at 1 800 296 1996 10a m 4p m EST Monday Friday except federal holidays or you may write MVAC s Recycling Program Manager Stratospheric Protection
506. mostat Gasket 3 P N N3C1 15 173 Qty 1 AAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAARAAAAAAAARARAAAAA AAAARAAAAA Water Pump Kit 3 P N 3 1 15 8520 2 Qty I S AAAAAAAALAAAAAAAPARAAAAAAAAAAAAAAAAARAAABARAARAAARARAARRARAAARAA 3 Replacement of the part is only required if there is 3 3 currently a coolant leak or if there has been a coolant 5 3 leak repair claimed and approved in the vehicle s history AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU One sheet of each of the labels listed above has been supplied with the dealer notification Additional labels are available through HELM Inc at 800 782 4356 Recall related labels are supplied at no charge WARRANTY INFORMATION VEHICLES WITH A HISTORY OF A COOLANT LEAK If the following conditions are met then the vehicle has experienced a coolant leak Any vehicle that has had a warranty claim paid for a Part Number Main Cause PNMC that matches the last five positions of the numbers listed below and one of the Symptom Codes listed PART NUMBER MAIN CAUSE PNMO LAST FIVE POSITIONS 02200 13530 1353X 1354X 13681 13691 13692 13640 15010 15100 5116 15140 15150 15162 15171 15172 15173 15174 15175 1517Y 5182 15183 15184 15185 15186 15200 15203 15205 15350 15355 15359 535X 15380 15610 15611 99008 SYMPTOM CODE TABLE
507. move the anchor clip from the right lower console panel S Fig 1 2 Remove the right lower console panel See Fig 1 Lower Console Panel 94G54003 Fig 1 Console Panel Removal 3 Fold back the carpeting and pull down the antenna connectors See Fig 2 RADIO REMOVAL TIPS W CD PLAYER CAT T NO 018 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 42PM Connectors 94H54004 SS Fig 2 Exposing Antenna Connectors 4 Disconnect the antenna connectors 5 Remove the service hol using a small flat bl Tule le covers from both the radio and CD player ade screwdriver wrapped with tape See CD Player Unit Remove hole cover with flat screwdriver 94154005 Fig 3 Hole Cover Removal 6 Push the stereo removal tool SST Part No 49 UNO1 050 into the holes on the CD player until it locks firmly See Fig 4 NOTE This tool is used on the foll 1992 93 MX 3 1993 RX 7 owing models RADIO REMOVAL TIPS W CD PLAYER CAT T NO 018 92 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 42PM 1992 93 MX 6 1991 92 Navajo 1992 93 626 1992 929 QV Ia ESS N Tool Insertion Holes left side shown right side similar 94J54006 CD Pla
508. mptoms should have the problem verified and if necessary corrected REPAIR PROCEDURE 1 Verify the complaint 2 Remove the control panel and the heater control unit See Fig 1 Refer to section G of the BETM for removal instructions Eigg a AIR CONDITION MALFUNCTION HAZARD SWITCH CONTACTS CAT U NO 95 09 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 20PM Check Hazard Warning Switch 2 VE Terminal 1994 5 G 06 1993 G 01 Condition Removing Control Panel Heater Control Unit 3 Check the hazard warning switch terminals Refer to informwtion in the T TERMINAL CONNECTION EXAMPLES for problem examples the femal terminals are damaged expanded remove the switch from the A C control unit and replace it with a new part If the terminals are normal re assemble and test If problems Still exist refer to the BETM or workshop manual for troubleshooting information CAUTION Avoid damage to pins by inserting the connectors straight Refer to TERMINAL CONNECTION EXAMPLES TERMINAL CONNECTION EXAMPLES MALE CONNECTORS 1 Hold the housing when connecting and disconnecting 2 To avoid connector pin damage a lign the connector and housing at the appropriate angle Slightly wiggle the connector right an
509. n 2 Intake System Inspection check the following If the air hose is coming off If oil is present inside the hose and there is no sign of breakage remove the oil It is not necessary to replace the hose If the hose is broken replace the hose with a new part and tighten to the specified torque Tf the hose is loose coming off insert properly and tighten to Specified torque NOTE The fuel connector bolt torque should be adjusted to 240 360 kgs cm 208 312 in lbs CAUTION Do not allow foreign material to enter related parts when replacing or reinstalling intake system parts SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM 3 Compression Measurement 4 Turbocharger Operation Controls Inspection TURBOCHARGER OPERATION CONTROLS INSPECTION TABLE UAAAKAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAL 3 Part Name 3 Inspection 3 Procedure 3 3 Item 3 3 3 Check Valve A 3 Reverse Flow After checking the check 3 3 and B 3 valve confirm that air 3 3 hoses C D E F are
510. nal fluid can be purchased directly from Kent Moore Complete Operating Instructions J41763 Adapter Kit A T Oil Cooler and Line Flusher for Mazda vehicles FLUSHING PROCEDURE 1 Backflush Cooler Starting At The Cooler OUT FWD Line Fitting 2 Reverse Lines And Flush Again Starting At The Cooler IN Line Fiting See Fig 1 Fig Te A T OIL COOLER FLUSHING EQUIPMENT GUIDELINE CAT J NO 96 01 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM Flushing Procedure 1 Backfiush Cooler Start ing At The Cooler OUT Line Fitting 2 Reverse Lines And Flush Again Starting At The Cooler IN Line Fit ting 95153536 Transmission and Cooler View NOTE Refer to the workshop manual for cooler location fittings on A4LD 4R44E and LA4A EL transmissions WARRANTY INFORMATION App micro icable warranty information will be included in the 1996 SRT END OF ARTICLE AUTOMATIC TRANS COOLER LINE FLUSHING PROCEDURE CAT K NO 005 98 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM ARTICLE BEGINNING TECHNICAL SERV ICE BULLETIN AUTOMATIC TRANSMISSION COOLER LINE FLUSHING PROCEDURE Model 5 Category Bulletin No Date DESCRIPTION
511. ncluding vehicles with a VIN of JMIFC3 L0806489 1993 RX 7 ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM 1 Check the air intake temperature sensor resistance A Remove air flow meter and allow to sit until its temperature is the same as the ambient temperature B Using a multi tester measure and record the resistance of the intake air temperature sensor terminals THAA E2 and the atmospheric temperature at that time See Fig 3 for terminal identification _ m Measure R sistance 94H53030 Fig 3 Air Flow Meter Terminal NOTE Use a multi tester with an accuracy equivalent of the FLUK 70 series CAUTION Refer to Fig 3 and the Standard Values table when measuring resistance STANDARD VALUES TABLE U AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Ambient Temp 3 Resistance Ambient Temp 3 Resistance 3 F 2 K Ohms 3 F 3 K Ohms 3 2 O 6 T87 70 2 24 9 3
512. ndred thousand ozone molecules WORLDWIDE ACTION TO PROTECT THE OZONE LAYER The United States has joined over 135 other countries in a global effort to protect the ozone layer as a Party to the international treaty known as the Montreal Protocol In 1990 these countries agreed to phase out production of ozone depleting substances including CFC 12 by the year 2000 The 1990 Clean Air Act Amendments the Act incorporated this production phase out data and also addressed the us and emission of these chemicals President Bush later pledged to halt almost all U S production of CFC s by the end of 1995 Section 609 of the Act gives the EPA the authority to establish requirements to prevent the release of refrigerants during the servicing of motor vehicle air conditioners Recycling of CFC s can occur at minimal cost and without damaging motor vehicle A C systems The following sections describe the requirements of the law and its potential impact on the service industry CLEAN AIR ACT REQUIREMENTS APPROVED EQUIPMENT Technicians repairing or servicing motor vehicle air conditioners must us ither refrigerant recover recycle or recover only equipment approved by the EPA Recover recycl quipment both recovers the refrigerant from the motor vehicle and processes it through an oil separator a filter and a dryer Approved recover recycle machines meet the technical specifications of SAE Standard J
513. ne for approximately 3 minutes at 2 500 3 000 rpm NOTE When the cooling fan has cycled on and off twice th ngin has reached its normal operating temperature 2 Test the vehicle as soon as possible after th ngine has warmed up Keep th ngine at operating temperature during the test END OF ARTICLE ENGINE PINGING KNOCK PREMIUM FUEL RECOMMENDATION CAT F NO 018 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 59AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN PREMIUM FUEL RECOMMENDATION Model s 1992 Mazda 929 1993 Mazda RX 7 1993 Mazda 626 V6 Engine 1993 Mazda MX 6 V6 Engine Category F Bulletin No 018 92 Date 5 13 92 DESCRIPTION If the following problems are encountered on the models shown below it may be the result of using a lower octane non premium fuel Engine Detonation pinging Engine Knock Lack of Power NOTE Problems listed are not model specific Customers experiencing any of the above symptoms should be referred to page 3 2 or the back cover of their Owner s Manuals The information states Your Mazda vehicle will perform best with premium unleaded fuel having an octane rating anti knock index of at least 91 Dealers providing a full tank of fuel to customers upon delivery of new vehicles should use premium
514. nes ar the need to replace th ngine the foll engine Engine Electrical owing components must be utilized ool Fuel 1 Av ing System Parts 3 Intake And Exhaust System Parts 4 F 5 WARRANTY INFORMATION Partial ngines ar vehicle warranty or for whichever is warranted ngin Parts And Emission Control Parts Clutch And Or Flywheel Copyright 1998 Mitchell Repair Information Company LLC ace from the original for the remainder or the original the first 12 months after installation of the longer All partial engine partial ngin DCSM NEW ENGINE LONG BLOCK B TRUCKS replacement will REPLACEMENT PROGRAM NEW ENGINE AVAILABILITY PARTS TABLE UAAAAAAAAAAAAAAA 3 Year Model warranty repairs of the require prior authorization from the 3 Engine P N Gasket P N 3 Remarks E ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1979 84 B2000 3 HEA4 23 800 8AU1 23 900 gt 3 3 1986 87 B2000 TEY a 3 1987 89 B2200
515. ng Bulletin No 002 93 Date 7 30 93 DESCRIPTION Since May 15 1993 government regulations mandate warning labels for vehicles fitted with R 12 CFC based air conditioning units Air conditioning units supplied from MANA as of MAY 17 1993 contain these labels The label must be attached to the vehicle window glass at the time of air conditioning kit installation and can only be removed by the retail buyer of the vehicle Refer to Fig 1 to determine label installation location NOTE Depending on model the label can be installed in 3 different locations Additional labels can be ordered through the Mazda parts department using the PARTS INFORMATION TABLE R 12 CFC WARNING LABEL INFORMATION CAT U NO 002 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 08AM WARNING Contains CFC 12 a substance which harms public health and environment by destroying ozone in the upper atmosphere Contents of the label Label must be readable from outside the vehicle 323 Protege Position label RX 7 Position label MX 3 MX 5 626 MX 6 929 MPV 1 3 inches from the edge 1 3 inches below the shaded Position label 1 3 inches from the of the glass portion of glass and 1 3 inches edge of the glass 9465319 from the edge of the glass Fig 1 Location of R 12 Label INSTALL
516. ng has been increased to eliminate the noise See Fig 2 WORKSHOP MANUAL CORRECTION FUEL SYSTEM CAT W NO 040 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 40AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WORKSHOP MANUAL CORRECTION VARIOUS CORRECTIONS Model 5 1993 Mazda RX 7 Category W Workshop Manual Corrections Bulletin No 040 92 Date 11 19 92 DESCRIPTION Attached are pages for the 1993 RX 7 Workshop Manuals which required corrections for the reasons listed below 1993 RX 7 A 9 correction to the Inspection of Cooling System text F 67 correction to the Self Diagnosis Checker Chart F 137 correction to throttle illustration valve operation in relation to temperature F 158 correction to terminal 3D Test Condition items F 160 correction to terminal 3M Remark item F 172 correction to terminal 3D Test Condition items F 174 correction to terminal 3M Remark item CORRECTIONS PAGE A 9 INSPECTION OF COOLING SYSTEM CORRECTION Inspection Of Cooling System Check the cooling system hoses including the heater hoses for cracks or wear If necessary replace the hoses 2 Check the cooling system for leaks by applying a pressure of 142 kPa 1 45 kgf cmy 20 6 psi with a radiator cap tester NOTE Do not pre
517. nge RARAARRARAARRARAAAAARARARAARARAARAARARAARARARARAARAAAA 2 1993 94 RX 7 3 JMIFD33 P0200001 R0302076 3 3 NOTE can be replaced by any letter or number U SERVICE PROCEDURES RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM REPLACEMENT OF THE CAP KIT NOTE If the vehicle has been sold perform steps 52 55 before preceding with step 1 To be performed on ALL vehicles 1 Loosen the bolts of the filler cap body Remove and discard the body and cap Replace body cap and Oo 2 Remove and discard the radiator cap replace it with a new one from the surge NOTE If vehicle is in inventory not sold proceed 98G51645 I Fig 1 Body Cap and O Ring REPLACEMENT OF THROTTLE HOSE To be performed on ALL customer sold vehicles ring with new ones from kit tank and to step 56 RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7
518. nrs both sides 3BMX 1 2 R amp R POI R amp R PO R amp R P0102ARX 0 5 P0102ARX 0 3 R amp R bo PO208CRX 0 9 PO208CRX 0 4 Ors one side 1993 94 1995 th side hrs 1993 94 hrs 1995 Machin 3AMX 0 7 Machin PO on vehicl one sides Ors vehicl P0113BMX 1 2 on nrs both sides R amp R one sides PO104ARX 0 4 P0104 R amp R PO PO 04 04 R amp R on P0102ARX 0 3 R amp R P0208CRX 0 5 hrs 1 hrs 1 993 94 995 993 94 995 hrs 1 hrs 1 e side hrs both side nrs Machin P0113AMX 0 7 on vehicl one sides nrs Machin 3BMX 1 2 PO on vehicl nrs both sides R amp R POI R amp R PO R amp R Ors Ors one side VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Article Text p 10 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM Labor Operation P0
519. ntification 1995 MILLENIA O RING DESCRIPTION TABLE aI 3 Pipe O Ring 3 Part Numbers 3 Quantity 3 Ring 3 Size 3 Size D X T 3 and 3 Per 3 Code 3 3 Kit Numbers 3 Vehicle z 3 G 3 16mm 3 13 4 x 2 4 3 LB57 61 J1X 3 3 3 3 axial 3 3 3 3 oO OK t Bg Bate 9 Che95o 36 17 295 ZZLO 61 J19 KIT 2 3 PE 3 5 8in 6 1 2 1 8 3 C003 61 J17 4 3 U NOTE Part numbers ending in J1X are delivered in quantities of 10 See Fig 13 for O Ring Identific
520. ntinuous Over all Ranges Does lack cf power occur over fuil range of engine speeds or above 3 000 RPM exciusivety Repair or replace as necessary Over 3 000 RPM improper secondary T C operation 4 Extension Manifold Throttle Body Intake Manifold Fresh Air Duct NOTE The flow chart above contains numbers inside parenthesis This number corresponds with the step on page 4 Component Troubleshooting and Inspect ion Procedure To Front RENE Turbocharger 98051617 Fig 1 Driveability Troubleshooting Tips Poor Power Idle Hesitates GENERAL TROUBLESHOOTING TIPS SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM TROUBLESHOOTING CHART AARAARARAARARARAAAAAAARAAARAAAARARAARAAAARARAAAARAAAAAAAAAAAAAAA 3 Trouble 3 Possible Cause AARRARARRARARARAARARAARARAARARAARARAARARAARARARAAAAAAARARARAARAAA 3 Engine will not start 7 On older vehicles the injectors may Spark plugs are wet or leak under extremely high pressures fouled developed during the fuel system 3 pressure test 3 Remove and clean plugs x With plugs remove hold the throttle completely open and crank 3 3 3 3 the engine to dechoke DO NOT REPLACE THE INJECTORS njectors will not leak
521. ntity 2 Fig 8 Navajo 94 B Truck Air Conditioning System Diagram END OF ARTICLE AIR CONDITION MALFUNCTION HAZARD SWITCH CONTACTS CAT U NO 95 09 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 05AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN AIR CONDITIONING MALFUNCTION Model 5 1993 95 Mazda RX 7 Canadian Category U Heater amp Air Conditioning Bulletin No 95 09 Date August 1995 APPLICABLE MODELS VINS All 1993 95 RX 7 vehicles with a VIN of JM1FD333 80400026 and lower DESCRIPTION Either of the following conditions may occur when the air conditioning system is operated No compressor engagement when A C is switched on Air flow mode switch fixed in defrost position m Ihese conditions may be caused by insufficient contact at the hazard switch connector 1994 95 G 06 1993 G 01 See Fig 1 NOTE The hazard switch harness also contains the A C control connector m This improper connection does not affect the hazard switch operation Changes in the production process have eliminated this problem Customers complaining of the above symptoms should have the problem verified and if necessary corrected REPAIR PROCEDURE 1 Verify the complaint 2 Remove the control panel and the heater control unit See Fig 1 Refer to section G of the BETM for rem
522. nto the gear This will hold the gear in place while prying 6 After the RS gear is pried loose remove the one bolt used to hold it in place and remove the RS gear assembly 7 Remove the O ring and oil seal and clean the RS gear After RS gear is cleaned use shop air to remove any remaining debris See Fig 2 8 Apply a small amount of oil to the new O ring and oil seal and install OIL LEAK AT REAR STATIONARY GEAR O RING CAR FIX CAT B NO 003 98 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 35AM 9 Install the RS gear Tightening torque 16 22 N m 0 Install remaining parts in the reverse order of removal 1 Verify repair REAR STATIONARY GEAR OIL SEA 97B58611 Fig 1 Rear Stationary Gear Oil Seal amp Bolt Insert Screwdrivers REAR STATIONARY GEAR O RING L D OIL SEAL 97C58612 Fig 2 Rear Stationary Gear Oil Seal amp Bolt Remove amp Clean PARTS INFORMATION OIL LEAK AT REAR STATIONARY GEAR O RING CAR FIX CAT B NO 003 98 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 35AM PARTS INFORMATION TABLE
523. ny LLC Saturday August 25 2001 10 24AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN RIDE QUALITY Model s 1993 Mazda Models Category Q Bulletin No 002 92 Date 7 16 92 DESCRIPTION Vehicle tires are inflated with excessive air pressure during assembly in order to properly seat the tire bead and to prevent flat spotting during storage Excessive tire pressure can increase steering wheel vibration and effect overall ride of the vehicle INSPECTION amp ADJUSTMENT PROCEDURE Check and adjust the tire pressure at pre delivery inspection and any other service interval The proper tire inflation values are shown in Fig 1 and can also be found on the vehicle certification label located on the driver s side door 94C53886 Fig 1 Location of Vehicle Certification Label TIRE PRESSURE SPECIFICATION TABLE Model 3 Front 3 Rear B AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 323 Protege 3 32 psi 3 32 psi A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 626 MX 6 3 32 psi 3 26 psi 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 929 3 28 psi 3 28 psi 3 RIDE QUALITY PROPER TIRE INFLATION CAT Q NO 002 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 c
524. o 64 e Dropping resistor resis tance Only No 64 Open or short circuit of sclenoid valve wiring sor Solenoid valve shift A Solenoid valve clutch Solenoid valve loukup Solenoid control 94H55506 Solenoid valve shift B e overrunning Solenoid valve line pressure lockup Fig 1 Service Code Number Reference Chart SERVICE CODE 01 DIAGNOSTIC TABLE WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM UAAAAAAAAAAAAAAAAAAAAAAAAAAAAABAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAL 3 Service Code No 01 3 Engine RPM Signal AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Step Inspection Action 3 3 1 Are there any poor 3 Yes Repair or replace connector 3 3 connections at 3 3 3 distributor engine AA AAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 control unit and EC AT 3 No 3 Go to next step 7 3 control unit connectors x s
525. olt with an air impact wrench When installing the new fuel hose hold the fuel distributor by hand and torque The fuel connector bolt torque should be adjusted to 240 360 kgs cm 208 312 in lbs Fuel Hose Clips The double clips used on the primary fuel distributor inlet hose are narrower than the other clips They also have a red holder The single clips for use on the secondary distributor outlet hose is wider and has a pink holder uel System Pressure Test It is essential that this test be roperly completed The fuel line clips may appear to be properly eated when in fact they are slightly mispositioned Only when his pressure test is performed for the full five minutes can you e certain that all joints are well sealed O ct nj hen performing fuel system leak test it is important to connect he battery negative cable and then install jumper wire from the round to the fuel pump terminals in the diagnostic connector efore tuning the ignition switch on When the test is completed urn the ignition switch off remove the jumper wire and then disconnect the battery negative cable Failure to follow this order could result in damage to electrical components such as the PCM ct OQ cf zi Be sure to use the proper 10mm nuts to install the coil assembly The proper nuts have grooves on the underside to ensure a complet ground Be sure that the O ring gasket is pro
526. oltage Engine coolant tem perature switch Cooling fan relay Refer to F 146 1 Cooling fan relay TFA terminal of data link connector is grounded Refer to F 146 1 Below 1 0 Cooling fan control module terminal J Ground Below 1 0 SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Fig 10 Article Text p 13 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM B Battery positive voltage Terminal Signal Connected to Test condition Voltage Possible V malfunction ENCOES ERE prec A E BEA EC MADRE BESSER o Power supply Ignition switch OFF Below 1 0 Main relay Ignition switch ON B Power supply Condenser Battery Constant A C fuse fan 98G51744 Main relay Terminal Voltage Chart K P COOLING FAN RELAY NO 1 2 3 4 1993 RX 7 INSPECTION 1 Disconnect the cooling fan relay 2 Apply battery positive voltage and ground to terminals A and B of the cooling fan relay See Fig 11 3 Check continuity of the relay TERMINAL CONTINUITY TABLE UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Operation 3 A Type Terminals D E 3 3 3 B Type Terminals C D
527. om Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 24AM AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA MX 3 I 3 3 6L 3 32 psi 3 32 psi 3 8L 3 28 psi 3 28 psi 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA MX 5 Miata 26 psi j 26 psi AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA RX 7 3 32 psi E 32 psi s AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Navajo A 26 psi 3 26 psi 3 7 B Series 3 3 3 3 4 X 2 3 26 psi 3 35 psi 3 4 4 3 28 psi i 31 psi I AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA MPV 3 35 psi i 32 psi 3 U w w w w w END OF ARTICLE STEERING WHEEL SLIGHTLY OFF CENTER CAT N NO 001 96 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 10 24AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN STEERING WHEEL SLIGHTLY OFF CENTER Model 5 1989 97 Mazda MPV 1990 97 Mazda 323 Protege 1990 97 Mazda MX 5 1992 95 Mazda 929 1992 95 Mazda MX 3 1993 95 Mazda RX 7 1993 97 Mazda 626 MX 6 1995 97 Mazda Millenia Category N Steering System Bulletin No 001 96
528. om Duty Solenoid 94E59315 Fig 33 Removal of Bolts from Duty Solenoid 9 Disconnect the air pipe at joint A shown in Fig 33 10 Disconnect the AWS hose and the air duct B at the joint as shown in Figs 34 Cover Outlet With Shop Towel 94F59316 Fig 34 Disconnecting the Air Pipe amp Hose 11 Remove the air intake pipe from the outlet of the turbo and cover RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 26 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM the outlet with a shop towel 12 Remove the air duct from the inter cooler 13 Remove the hoses from the extension manifold See Fig 35 NOTE Disconnect the hoses at the locations indicated by the arrows shown in Fig 35 only 14 Remove the harnesses from the extension manifold See Fig 35 Remove these four parts referring to Step 16 Pressure Sensoc PCV Hose 1 Double Throttle Control Hose 2 Purge Control Hos ACV Vacuum Hose 3 Vacuum Chamber EGR Vacuum Hose Hose 94G59317 Fig 35 Removing Hoses amp Harnesses From the Extension Manifold NOTE Use the above illustration to determine the hose location 15 Fig 16 RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 27 1993 Mazda RX7 For www iluvmyrx7 com
529. ompartment fires can result Therefore these vehicles must be repaired by replacing the fuel hoses with modified fuel hoses SUBJECT VEHICLES VEHICLE INFORMATION TABLE AAAAARARAAAAAARAAAAAARAAAARAAAAAAAAAAAAAAAAAAAAAA 3 Model Year amp Model 3 Vin Range RARAAARARAAARAAAAARARARARRARARAAAARAAARARARARAAAAR 3 L993 RX 7 3 JM1FD33 PO200001 210660 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1994 95 RX 7 3 JM1FD33 RO300001 S0400026 3 Can be replaced by any letter or number 3 U OWNER NOTIFICATION The owners of the subject vehicles will be notified by first class mail around May 12 1995 REPAIR PARTS An initial quantity of Recall Labels are enclosed with this Service Bulletin Part Number 9999 94 5032E F Additional quantities can be ordered through normal parts ordering channels Following completion of the repair fill out the Recall Label with the appropriate information and affix it to left front driver s door as shown in Fig 31 SPECIAL NOTE NOTE amp Fig Under separa was shipped with a note is the only repairs for RX 7 FUEL LEAKAGE RECALL CAM
530. on is functioning Check the alternator and related harness according to appropriate service information 94D53036 LCHARGE Fig 9 Charge Indicator Light 2 Fluctuate th ngine RPM and listen for alternator bearing or engine belt noise If noise is present inspect for loose or damaged belt or damage to the alternator bearing NOTE Perform the above inspection with the vehicle headlights illuminated 3 Turn off the ignition and all accessories Connect a load tester VAT 40 or equivalent 4 Apply the load test referring to the LOAD TEST TABLE The final voltage must be above the standard minimum value shown in MINIMUM VOLTAGE TABLE LOAD TEST TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAR 3 Model 3 Test Load Amps ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 323 Prot 3 180 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 626 MX 6 3 174 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 929 3 180 3 3 195 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 MX 3 2 150 3 3 3 180 3 3 3 165 3 3 5 3 105 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 RX 7 3 180 3 ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 3 w w 3 MPV 2 Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM 165 3 L95 3
531. on the primary fuel distributor outlet side See Fig 18 NOTE When installing do not twist the O ring Replace the bolts with modified ones S letter G in Fig 18 Tightening Torque 25 36 kgf cm 22 31 in lbf Fuel Hose N3Z1 13 420 Bolt 99796 0510 x 2 pcs O ring Bolt B 94E59331 Fig 18 Installing Primary Fuel Distributor Outlet Modified Hose 27 1 Install the hose on the inlet side of the primary fuel distributor See Fig 19 Fuel hose N371 13 415 Submerge the hos nd with the white mark into adhesive RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM Use adhesive specially prepared for this work NOTE Be careful not to use another adhesive Install the hose white mark side within five minutes after applying adhesive NOTE Before installing the hose degrease the pipe for better adhesion Fuel hose N371 13 415 White pain 94F59332 Fig 19 Installing Hose on Inlet Side of Primary Fuel Distributor Submerging Hose End with White Mark into Adhesive 27 2 Install the clips on the hose of the inlet side of the primary fuel distributor NOTE Use two clips on the fuel distributor si
532. opyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 45PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SPEEDOMETER REPLACEMENT PROCEDURE Model 5 All Mazda Models Category AD Administrative Bulletin No 003 97 Date February 25 1997 DESCRIPTION In accordance with Federal regulations follow the procedures listed below when replacing a speedometer NOTE 1 Mazda vehicles are manufactured with tamper proof speedometers and the mileage CAN NOT be altered or adjusted 2 When a speedometer is replaced the new speedometer will read zero 3 This procedure is extremely important to accurately represent actual vehicle mileag 1 The Speedometer Replacement Label referenced below is available through the Mazda Program Center for a limited time Mazda Motor of America Inc is providing 1 sheet of 20 labels with this bulletin REPLACEMENT PROCEDURE 1 Remove and replace the speedometer according to the workshop manual 2 Complete the following information on the Speedometer Replacement Label See Fig 1 a Mileage before speedometer replacement b Date of replacement c Dealer code 3 Attach the label to the driver s side B pillar 4 Complete the Speedometer Replacement Record in the Warranty Information Booklet See Fig 1 Fig 1 SPEEDOMETER REPLACEMENT PROCEDURE
533. or Over 3 3 1992 93 929 3 3 3 1993 626 MX 6 3 3 3 MX 3 All 3 3 3 MX 5 All 3 3 3 1989 91 RX 7 3 56 or Over 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 1993 RX 7 3 53 or Over 3 U 9 If the value of fuel pressur Max is below standard measure the voltage at the fuel pump connector vehicle side using the procedures below A Reinstall the jumper wire and turn the Ignition on Refer to steps 6 and 7 of the previous page B Connect test leads to the fuel pump positive and negative terminals and measure the voltage at the fuel pump connector vehicle side S Fig 8 for illustration ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 12 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM 94C53035 Fig 8 Measuring Fuel Pump Voltage NOTE Do not disconnect the fuel pump connector If the voltage is above the standard value replace the fuel pump f the voltage is below standard check for a damaged harness relay or a poor ground at the pump Standard Value 8 5V and over 93 RX 7
534. or bolt torque should be adjusted to 240 360 kgs cm 208 312 in lbs Fuel Hose Clips The double clips used on the primary fuel distributor inlet hose are narrower than the other clips They also have a red holder The single clips for use on the secondary distributor outlet hose is wider and has a pink holder uel System Pressure Test It is essential that this test be roperly completed The fuel line clips may appear to be properly eated when in fact they are slightly mispositioned Only when his pressure test is performed for the full five minutes can you e certain that all joints are well sealed O ct nj hen performing fuel system leak test it is important to connect he battery negative cable and then install jumper wire from the round to the fuel pump terminals in the diagnostic connector efore tuning the ignition switch on When the test is completed urn the ignition switch off remove the jumper wire and then disconnect the battery negative cable Failure to follow this order could result in damage to electrical components such as the PCM ct OQ cf zi Be sure to use the proper 10mm nuts to install the coil assembly The proper nuts have grooves on the underside to ensure a complet ground Be sure that the O ring gasket is properly seated on the base of the oil filler The gasket may come off during removal without being noticed When insta
535. ose RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Double throttle control actuator hose Rear secondary injector coupler 29 Replace the gasket between th xtension manifold and the intake manifold with a new one install the extension manifold and then install the harnesses and the vacuum tubes See Fig 22 install New Gasket 98C51666 Fig 22 Extension Manifold Gasket 30 Install throttle body with new gasket RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 18 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Install New Gasket 98D51667 Fig 23 Throttle Body Gasket NOTE Be sure the gasket is installed in the correct direction A projection on the gasket faces the double throttle body side 31 Attach the water hoses at the outlet and inlet of the throttle body 32 If the vehicle has no history of coolant leaks and no leaks were detected during initial testing proceed to step 51 REPLACEMENT OF THE WATER PUMP KIT AND THE THROTTLE HOSE KIT To be performed on vehicles that hav xperienced overheating or leaked during the pressure test 33 Drain coolant and retain in app
536. ose End with White Mark into Adhesive 27 2 Install the clips on the hose of the inlet side of the primary fuel distributor NOTE Use two clips on the fuel distributor side Place the fuel distributor side clip claws on the top and the other one on the bottom For the directions of the clip claws see Figs 54 and 55 Insert the hose to the pipe bulge Match the edges of the clip and the hose end Replace all hose clips with new ones Do not use clips other than those included part number below Be careful not to place the clip on the pipe bulge Clip N32Z1 13 157 x 2pcs Protector N3B7 13 428A RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 38 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Place the fuel distributor side clip claws on the top and the other one on the bottom 94G59333 Insert the hose to the pipe bulge NO CLEARANCE Match the edges of the clip and the hose end Fig 54 Installation of Clips on Hose Install the protector Protector foci AU Tuo 5 f 94H59334 Fig 55 Installation of Protector 28 Install the fuel hose on the secondary fuel distributor See Fig 56 NOTE Place the connector stopper on the secondary fuel distributor body then tighten
537. oval instructions Eigg a AIR CONDITION MALFUNCTION HAZARD SWITCH CONTACTS CAT U NO 95 09 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 05AM Check Hazard Warning Switch 2 VE Terminal 1994 5 G 06 1993 G 01 Condition Removing Control Panel Heater Control Unit 3 Check the hazard warning switch terminals Refer to informwtion in the T TERMINAL CONNECTION EXAMPLES for problem examples the femal terminals are damaged expanded remove the switch from the A C control unit and replace it with a new part If the terminals are normal re assemble and test If problems Still exist refer to the BETM or workshop manual for troubleshooting information CAUTION Avoid damage to pins by inserting the connectors straight Refer to TERMINAL CONNECTION EXAMPLES TERMINAL CONNECTION EXAMPLES MALE CONNECTORS 1 Hold the housing when connecting and disconnecting 2 To avoid connector pin damage a lign the connector and housing at the appropriate angle Slightly wiggle the connector right and left then slowly insert straight into the assembly Refer to Fig 2 and Fig 3 Avoid forcing the connection or mis alignment AIR CONDITION MALFUNCTION HAZARD SWITCH CONTACTS CAT U NO 95 09 Article Text p 3
538. own in Fig 5 3 3 3 3 Is input voltage of 1 3 3 3 3 throttle sensor IVO at 3 i 3 3 3 EC AT control unit OK RE ES Fig SERVICE CODE 55 DIAGNOSTIC TABLE 4 53 WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 3 3 3 3 3 ww www iw 3 3 3 3 3 3 3 3 3 w w www w 5r Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM Applicable Voltages 3 No Go to next step 1 1 1 throttle valve 3 fully closed 3 3 3 4 0 4 5 throttle valve 3 2 3 fully opened 3 3 3 AAAAAAAAAARAAAARARAARARAARAAAAAAAARARAAAARARAARARAARARAAAAAAAAAAAAAA Connect a circuit tester to Yes Go to next step terminals 2A and ground as 3 shown in Fig 5 Is input voltage of 3No Check voltage at 3I terminal throttle sensor VREF at 3 of engine control unit 3 EC AT control unit OK 3 3 Voltage 4 5 5 5 volts with Acceptable Voltages 3 3 ignition switch on 3 4 5 5 5 volts with ignition 3 If OK go to next step switch on 3 3 If not OK repair wiring 3 0 volts with ignition a 3 and or
539. p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 47PM CLAIM PROCESSING EXAMPLES Example 1 A 1994 626 Original Equipment Battery fails after the vehicle has been in service for 13 months with 11 000 miles on the odometer WARRANTY INFORMATION TABLE EXAMPLE 1 AAAAAAAAARAARARARAARARAARARAAAAAAAARAAAAAAAAARARAARAAAAAAAAAAAAAAAAA Claim Submission 3 Dealer Reimbursement 3 AAARAARAARAARAARRARAARAARAAARARAARAAAAAAAARAARAARRARAARARARRARAARARAA 3 Warranty type E 5 Warranty labor 3 3 rate 50 00 hr 3 3 Symptom code 20 3 3 3 Damage code 81 3 3 Vendor code KN212 3 3 3 Part number 3 3 3 main cause 0000 80 058R WB 3 3 3 Quantity 1 3 3 Pro Rate 50 3 35 67 DNP 40 50 3 Related part s 0 wet battery acid 3 3 is not required i 3 3 Labor operation G0501ACX 2 3 Labor Hours 0 5 3 25 00 3 3 3 Total 3 3 reimbursement 60 67 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAA 3 CUSTOMER S RESPONSIBILITY battery pro rate only 3 retail price 78 95 x 50 39 48 3 Example 2 A 1993 Protege battery has failed This is the second time the battery has failed The firs
540. pair Information Company LLC Saturday August 25 2001 07 06AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER DTC DIAGNOSTICS Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0597 07 Date May 1997 DESCRIPTION The diagnostic procedures for DTCs Diagnostic Trouble Codes in the Workshop manual don t always include the procedure to check related connectors that are within the DTC component s circuit Whenever performing diagnostic procedures always use the wiring diagram in conjunction with the Workshop Manual Check each related connector for the following Incomplete connection Loos ma terminals Terminals that are pushed out of their connectors Water inside the connector Terminal corrosion Also check each related harness for damage END OF ARTICLE HEATER HOSE CORE CONNECTOR DEALER HINT MT 0597 09 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 06AM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER DEALER HINT HEATER HOSE CORE CONNECTOR Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0597 09 Date May 1997 DESCRIPTION The following hint was submitted by George Beck of New London Mazda in New London Connecticut An easy way to disconnect the heater hoses from the heater core is to insert
541. pair Information Company LLC Saturday August 25 2001 07 26AM E 3 terminal and ground OK 3 No 3 Go to next step 7 3 Resistance 20 40 ohms q AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 4 3 Disconnect solenoid 3 Yes Check wiring and connectors 3 3 connector 3 3 from EC AT control unit to 3 3 Ts resistance between 3 3 solenoid valve shift B 3 3 3 ground and terminal C of 3 3 If OK go to next step 3 3 3 solenoid valve shift B j Tf not OK repair wiring 3 3 OK 3 and or connector 3 3 Resistance 20 40 ohms AARRAAARRARAARAARARARARRAAARARAARR 3 3 No Replace solenoid valve 3 3 3 3 shift B 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 5 Disconnect negative Yes Replace EC AT control unit 2 3 battery cable for at least 3 3 3 20 seconds E 3 Connect battery cable and No Intermittent poor connection 3 3 recheck for service cod 3 Check for cause E 7 Is Service code displayed 3 U EC AT CONTROL UNIT SOLENOID CONNECTOR SOLENOID VALVE SHIFT A 94155431 Fig
542. passenger side Remove the glove box Adjust the climate controls to the following settings F HGtIOD ont ELE Defrost Temperature Max hot Fat speed sa su ee 4 Recirculation fresh Fresh Check for leakage between blower unit and cooler unit air duct Check for leakage between cooler unit air duct and heater unit E Air duct is present only on vehicles not equipped with air conditioning Engine compartment Turn off the engine Raise the hood and visually inspect the following for proper sealing A C drain grommet A C pipes where they enter the cooling unit at the firewall Heater pipes where they enter the firewall All body harnesses that pass through the firewall Speedometer cable XOX OX HF SE HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM NOTE Do not perform the above checks with the engine running Item 3 Link and Wire Adjustment Remove the kick panel on the passenger side of the vehicle 2 Remove the glove box 3 Place the transmission in park or set manual transmission in neutral and set the parking brake 4 Start the engine and allow to idle 5 Set the climate controls to the following settings Temperature M
543. ped REFRIGERANT IN NEW CARS Automobile manufactures are responding to the CFC phase out by producing new vehicles with an alternative refrigerant called HFC HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM 134a This refrigerant does not deplete the ozone layer because it does not contain chlorine About half of the 1993 model year cars and almost all 1994 model year cars are equipped with HFC 134a air conditioning systems CHOICES FOR OLDER CAR OWNERS As for existing cars when the supply of CFC 12 is o longer available owners may modify their A C systems to accept the HFC 143a Since the HFC 134a works at a higher pressure than the CFC 12 retrofitting will require that some components be replaced EPA estimates that retrofits will cost between 100 800 00 The specific requirements will vary depending on the make model and age of the car and on the car s history of air conditioning servicing If you are having major service performed on you CFC 12 air conditioning system modifying the system may be appropriate Auto manufactures are currently working to identify retrofit procedures Most have toll free consumer hot lines which you can call to determine if retrofit procedures have been developed for our auto
544. perly seated on the base of the oil filler The gasket may come off during removal without being noticed When installing the Catch Tank during reassembly be sure to route the vacuum hose from the purge control and to the catch tank on t i ne he outside of the oil filler Otherwise the vacuum hose could nterfere in proper operation of the throttle linkage The Fan Control System fastener A is a gray plastic phillips screw in fastener Remove and discard the fastener The bolt at the top of the ECU should be loosened to allow the ECU to be slid down and away from the kick panel IL is not necessary to remove the wiring connectors from the ECU to perform this procedure Just move the ECU over toward the center of the passenger area floor SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM DRIVEABILITY TROUBLESHOOTING TIPS Lack of Power Rough idie and Hesitation Start Engine Check each solenoid and actuator operation 2 NOTE A problem may have occurred during assembly atter recali repairs were performed i e kinked loose or broken hose Remove Hose A Refer to Fig Beiow Within Specificaton Disconnect the knock sensor coupler Does condition ch
545. plice circuits for non factory accessories into existing wire harnesses Splicing of non approved accessories into the wire harness can increase the chance of water entering the harness and causing corrosion Splicing power circuits of non factory accessories can also cause faulty signals to be sent to electronic systems in the vehicle Separate fused power circuits should be run to non factory accessories if they are installed END OF ARTICLE OCTOBER 1995 SPECIAL TOOLS SHIPMENT CAT ST NO 007 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 40PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SPECIAL TOOLS OCTOBER 1995 Model 5 1988 96 Mazda Models Category ST Special Tools Bulletin No 007 95 Date October 24 1995 DESCRIPTION The NGS Program Card P N 49T0 88 010A version 2 0 refer to Mazda TSB Cat ST No 002 94 for additional information used with your New Generation Star tester has been discontinued It has been replaced by a revised card P N 49T0 88 010B version 2 01 that includes all 1996 model information Fig 1 is an illustration of this new Special Service Tool SST It is a Mazda Required Tool MRT and will be automatically shipped to your dealer by Mazda s tool vendor America Kowa Seiki Inc APPLICATION Refer to the NEW APPLICATIONS FOR NGS PROGRAM C
546. pment is approved Models listed for the first time in this update are in bold type TABLE 1 APPROVED UL RECOVER RECYCLE EQUIPMENT TA ERO AUL RE OER REC TOTE OT PEA Les te ie Suay UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAARAAAARA 3 3 TABLE 1 Manufacturer 3 Model A Gramkow RRC 3 E AES NTRON 3 Retriever 2 2AC and 2 2A 2 Airosol Company Inc g Chargette RC2000 RC2200 American Thermaflo 3 18000 3
547. pproximate distance the outside diameter will move for every 1 4 90 degree turn of the tie rod end Tie Rod End Turns vs Distance Moved Table AAAAAAAAARAARARARAARAAAAAAAAAAAAAAARAAAAAAAA Model 3 Approximate Distance 3 3 1 4 turn 3 3 1990 97 323 Protege 3 8mm with PS 3 i 3 11 12mm without PS 3 1992 95 MX 3 7mm 6 cyl 3 3 1993 95 RX 7 s mm ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1993 97 626 MX 6 9 10mm 3 1992 95 929 3 11mm I 3 1989 97 MPV 3 13mm 4x2 3 3 3 l2mm 4x4 i AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1990 97 MX 5 8mm with PS 3 3 3 10mm without PS 3 3 1995 97 Millenia 3 1Omm 3 U WARRANTY INFORMATION Applies To Verified Customer Complaints On Vehicles Covered Und
548. proper usage AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 3a Use diagnostic flow 3 3 3b Instruct on proper 3 chart to determine 3 system usage 7 3 repair procedure 7 U AAAAAAKAAAAAAAAAAAAAAAAAAAU UAAAAAAAAAAAAAAAAAAAAAAA 3 4 Use check sheet to perform repairs 3 AAAAAAKAAAAAAAAAAAAAAAAAU Diagnostic Procedures HEATING SYSTEM TROUBLESHOOTING CAT U NO 93 04 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM 1 Collect detailed complain the Customer Comment Sheet information from the customer using 2 Use the information collected on the Customer Comment Sheet to determine the nature of the complaint 3a Refer to the diagnostic flow chart and determine the necessary checks 3b After determining the complaint is of a usage nature instruct the customer on the proper operation of the system Use the Check Sheet to perform the necessary repairs
549. r 25 Remove the fuel hose from the primary fuel distributor RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 36 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM See Fig 51 NOTE When turning the screw be careful not to break the heads of the screws F two because they are tight Be careful not to damage the pipe at the hose insertion location on the primary inlet side 94D59330 Fig 51 Removal of Hose from Primary Fuel Distributor 26 Install the modified fuel hose on the primary fuel distributor outlet side See Fig 52 NOTE GI When installing do not twist the O ring Replace the bolts with modified ones S letter G in Fig 92 Tightening Torque 25 36 kgf cm 22 31 in lbf Fuel Hose N3Z1 13 420 Bolt 99796 0810 x 2 pcs O ring Bolt B 94E59331 Fig 52 Primary Fuel Distributor Outlet Modified Hose 27 1 Install the hose on the inlet side of the primary fuel distributor See Fig 53 Submerge the hos nd with the white mark into adhesive Use adhesive specially prepared for this work RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 37 1993 Mazda RX7 For www iluvmyrx7 com Copyright 199
550. r Under 14 1V Check for resistance between the battery and ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 16 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM terminals B and S f resistance is present repair the damaged harness and retest lf the voltage is still below 14 1V replace the alternator 14 1V to 14 7V No trouble with the alternator or battery ALTERNATOR AND BATTERY CHECK SHEET Dealer Name Technician Number Vehicle Year Model M T A T VIN Mileage Repair Order Number Repair Date 1 Customer Complaint 2 Was the customer s complaint verified Yes No 3 Reason for replacement Alternator output or battery voltage was out of spec Yes No 3 Reading Factory Spec 3 AAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAALAAAAAAAAAAABAAAARAAAARRARAAA Output Voltage 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Output Amperage z AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Instrument Used 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Battery Voltage Open Terminal 3 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
551. r __ Flare __ Shudder Vibration Doesn t shift Oil leakage Location __ Delayed engagement __ Hold OD off light flashing __ Erratic Shift Hunting __ Other Shifter range A P R N 2 S 1 L _ When shifting from _ to __ In what gear does it occur lst 2nd __ 3rd __ 4th _ N __ From gear __ to __ Vehicle speed MPH to __ MPH Throttle position __ Acceleration __ Kick down __ Decelerating Any Position __ Steady Position 5 Engine temp __ Cold __ Hot __ Any Temp Road condition Flat __ Uphill _ Downhill A C Switch position __ On __ Off Frequency __ Intermittent _ Always Description of other symptom TECHNICIAN DIAGNOSIS Trans fluid condition __ Normal Milky Burnt Particles Sludge Trans fluid level Normal High Throttle cable adjustment If applicable __ Normal Tight mm out of spec _ Loose _ mm out of spec Shift linkage setting Normal Out of spec Describe Trans range sensor Normal Out of spec Describe Diagnostic Trouble Code DTC None Code Throttle position sensor voltage __ Steady _ Yes Open V Closeq V AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 20 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM LINE PRESSURE DS Range L
552. r 6 aaoge UMOUS se s uonisod yeas peyeuBblsep eui 18 AUO pesn eq pjnoys Jepue xe eui Jey Jeujojsno ou urejdxe oj Ajiigisuodsei su e p au 5 Y 310N _xeo zs cag1_ xeg zs 9Ad4 X 9 S SAQH X 9 9 CAq1 xe9 2 9 9Ad3 Xt9 28 SAQ4 EP Xc9 9 BAQ9 X 9 S CAd 1 X 9 78 9AQ3 X 9 ZS cAH1 X 9 2G8 SAQ3 X 9 2S 9A04 X 9 2S SAQ4 X 9 2S 9AG4 X 9 ZS 4APE XE9 2S SAQ1A X 9 7S 3JAf8 Creme fesses P ER SE DE j x 23 XE9 2S NA9G X 9 28 ZA8d1 X 9 S 81 X 928 2Agd1 X 9 78 SAd 69 5 8 X 9 2S SAG1 X 9 2S 8A81 X 9 7S vA81 9 8 Xt 9 78 6Ad1 X 9 78 SAd l X 9 2S CAGdT X 9 78 8A81 X 9 ZS VAGT X 9 ZS gA 1 48 3 ou Zr X 9 ZS cAHT iepuejx3 you 6 Jepueix3 youl 8 eje1edes jees uoueq 1865 upueq JequinN Weg yeas pig yees puz uonisog 1595 ope ete p PR PR Dese L x 6LP6PEOL L0000 0 L v LE LINP Silu3s d 86 626 S6 26 626 68 88 L XH 96 56 929 66 86 ERR BE ERE EN a RE 3 XW 929 6 66 VIN 16 76 EXN S6 6 39510Ud 6661 30310848676 39310Hd 96 3531089 56 AdW 86 96 AdW S6 6 AdW 26 16 AdW 06 68 ISPOW 1A uoneoiddy AuiqereAy 19pu lx3 eg 1895 NOLLYMHOANI
553. r of America has instituted a comprehensive battery maintenance program at port facilities to maintain peak battery performance until delivery to the dealer After wholesale delivery it is the dealer s responsibility to maintain the condition of the batteries in new Mazda vehicles while in inventory and at the time of new car delivery Batteries must be periodically recharged to maintain a measured 12 4 volts or better Loss of battery voltage is dependent on ambient temperature demo use and time in inventory Mazda recommends voltage checks at one month intervals and just prior to retail delivery The maintenance and inspection process will vary based on dealer inventory and environmental factors that affect battery life i e extrem temperatures BATTERY MAINTENANCE RECORD Mazda has installed a Battery Check Tag on the mirror of all vehicles except B Series and Miata starting June 1 1996 The tag will document the maintenance efforts of the port personnel and subsequent maintenance of the dealership A sample of the Battery Check Tag is included in this bulletin DO NOT remove this tag from the mirror until retail delivery The dealer is responsible for entering the vehicle s battery voltage onto this tag on the following occasions Wholesale Delivery Planned Dealer Inventory Maintenance Retail Delivery NOTE Entries must be identified by the dealership employee n
554. rank angle sensor 3 3 3 input voltage of engin 2 3 and or wiring 3 E 3 RPM signal at engine 7 3 If OK replac ngin 2 7 3 control unit OK i 3 control unit 3 3 Acceptable Voltages 3 3 If not OK repair or 3 3 3 0 volts engine stopped 3 replace malfunction parts x 3 3 8 volts engine idling x and or wiring 3 7 3 1 8 2 2 volts engine 2 3 3 running at 3 000 rpm 3 3 3 3 3 with no load i 5 3 5 3 Disconnect negative 3 Yes Replace EC AT control unit z 3 3 battery cable for at least 3 3 3 20 seconds AAAAAKAAAAAKARAAAAAAKAAAAAAKRAAAAAAAAAA 5 3 Connect battery cable and No Intermittent poor connection 3 3 recheck for service cod 3 3 Check for cause 2 3 Is Service code displayed 3 U WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM ENGINE CONTAOL UNIT EC AT ENGINE RPM SIGNAL CONTROL UNIT PERNT NE M UR T U
555. ransaxle A Service Adviser Technician Check Sheet amp Diagnostic Flow Chart is provided with this bulletin See Figs 1 amp 2 These are useful tools in preventing unnecessary replacement of transmissions illustrating step by step diagnostics and are required for replacement authorization Additional pads of fifty 50 are available charge from Helm Inc For additional information regarding transmission transaxle diagnostics refer to the applicable workshop manual and or contact your regional distributor hot line ree of NOTE If the transmission oil cooler is not cleaned with the proper power flushing equipment prior to repair completion and comeback problems occur due to clogged oil cooler circuits the repair cost will not be warrantable RECOMMENDED POWER FLUSHING MANUFACTURERS EQUIPMENT TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Manufacturer Telephone Number Part Number Description 3 OTC 800 533 0492 3 60081 Portable Torque 3 3 Converter Oil Cooler Cleaner
556. ranty conditions After obtaining authorization the transmission must be ordered from the MANA Remanufacturing Operation office servicing your dealer MANA will require the following information before releasing a transmission MASH Authorization Number Vehicle retail date if under original warranty Repair date and mileage at the time of replacement if under parts warranty DEALER INVENTORY Transmission assemblies will be available for dealer stocking on November 1 1995 ORDERING LOCATIONS MANA Irvine Branch MANA Jacksonville Branch 1424 McGaw Ave 8601 Youngerman Court Unit 9 Irvine CA 92714 Jacksonville FL 32244 714 261 9429 904 779 5996 or 714 852 7225 FAX 904 77X5X X89 FAX 714 261 6573 NOTE Dealers in TEXAS should order transmission assemblies from the MANA Jacksonville Branch TRANSMISSION DELIVERY Normal delivery for transmissions ordered before 12 p m is two 2 full working days Example Order received before 12 p m Monday will be delivered Wednesday PART NUMBER INFORMATION See Parts Flash 95 20 for detailed applications and part numbers CORE RETURN PREPARATION AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM To ensure your dealer receives the 600 00 core credit
557. rd brake booster side bolt only 3 Install a rubber mount into the attaching bolt hole 4 Tighten rubber mount into the firewall Tightening Torque 0 7 1 1 kgf m 5 8 ft lb 5 Install vacuum pipe to the rubber mount retighten bolt loosened in step 2 al Tightening Torque 0 7 1 1 kgf m 5 8 ft lb PARTS INFORMATION PARTS INFORMATION TABLE 3 Part Number 3 Description Oty 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 F285 13 363 Rubber Mounting 3 AAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 9994 00 600 3 Nut Flange 3 3 WARRANTY INFORMATION Apples to verified customer complaints on vehicles covered under normal warranty Refer to the SRT microfiche for warranty term information Warranty Type A Symptom Code 80 Damage Code 9G Part Number Main Cause F285 13 363 Quantity 1 Operation No XX921XRX Labor Time 0 2 hr END OF ARTICLE VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN BRAKE JUDDER REPAIR
558. rday August 25 2001 06 55AM In SEL 3 11 Remove the air intake pipe from the outlet of the turbo and cover the outlet with a shop towel 12 Remove the air duct from the inter cooler 13 Remove the hoses from the extension manifold See Fig 4 NOTE Disconnect the hoses at the locations indicated by arrows only Remove these four parts referring to Step 16 Pressure Sensor PCV Hose 1 Double Throttle Control Hose 2 Purge Control Hose 3 Vacuum Chamber Hose ACV Nacuum Hose EGR Vacuum Hose 94G59317 Fig 4 Removing Hoses amp Harnesses From the Extension Manifold NOTE Use the above illustration to determine the hose location RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 7 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM 14 Remove the harnesses from the extension manifold See Fig 4 15 Remove the accelerator cable and the cruise cable See Fig 5 94H59318 Fig 5 Removing Accelerator Cable amp the Cruise Cable 16 Raise the extension manifold and disconnect the following harnesses vacuum tubes and hoses from the side indicated by the arrow only See Figs 6 7 amp 8 Harnesses Inlet Air Temperature Sensor AB Solenoid ISC Valve 5 Vacuum Tubes
559. rday August 25 2001 07 24AM 3 2 4 band 3 ADJ 2 ADJ 3 3 3 3 OD band 3 ADJ i ADJ 3 ADJ 3 3 INT band 2 ET 3 ADJ 3 ADJ 7 KAARRARAMAAAAAAARARAAARAARAAAAAAARRRAARAAAANAAAARARRAAAARAR i Low Rev band 3 ADJ 3 ADJ 3 AMAR AAAARAAAAAAAAAAAA AAAARA AAAAR AAAAR AAAARAAAARAAAARAARARARA 3 T R sensor ADJ i ADJ 3 ADJ 3 ADJ 3 3 Throttle cable 3 K j cue i 3 pressure 3 3 3 AAARAARRARAAAAARAARAARAARAARAARARARARAAAAARAAAAAAAAAAAARAAAA Modulator pin i ADJ 7 X ADT gE 3 AARAAAARAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 External linkage 3 ADJ 2 ADJ ADJ ADJ 3 AAAAAAAARAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAARBAAAAAAAAA ADJ Adjust as needed per W M authorization not 3 3 required 3 3 RPL Repair or replace as needed per W M authorization 3 3 not required 3 3 CMH Call MASH Hotline for REMAN ASSEMBLY authorization do not repair or replace component 3 3 1 Throttle cable not used on GF
560. re to use the hoses clips and gaskets designated in this procedure and do not reuse the removed parts 4 When installing the hoses be sure to check their locations in accordance with the instruction and install them correctly PROCEDURE A REPLACEMENT OF FUEL HOSE KIT To be performed on ALL customer sold vehicles 1 Start the engine 2 Remove the circuit opening relay See Fig 1 age E S A lt ein b LE 34D69314 Circuit a Relay Fig 1 Location of Circuit Opening Relay 3 After th ngine stalls crank the engine for 15 20 seconds to purge the injectors 4 Turn the ignition switch off 5 Install the circuit opening relay 6 Disconnect the negative terminal from the battery NOTE Record all preset stations on the vehicle s audio system prior to disconnecting the battery terminal 7 Drain coolant and retain in an appropriate container RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 8 Remove the bolts from the duty solenoid and the pressure chamber See Fig 2 Tightening Torque 70 100 kgf cm 61 86 in lbf Duty Solenoid Remove Bolts from Duty Solenoid 94E59315 Fig 2 Removing Bolts from Duty Solenoid 9 Disconnect the air pipe at joint A shown in Fig 3 A
561. rear upper side of the throttle water hose NOTE DO NOT DAMAGE fuel return hose 98G51660 Fig 16 Fuel Return Hose 24 Use long needle nose pliers to remove hose clamps and replace the rear throttle body wat RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM holders from clamps attach DO NOT DAMAGE ter hose with a new two new clamps with on S Fig 17 Remove Install New Rear Throttle Body Water Hose Use New Clamps this step ty of the above procedures ted the main fuel d perform D G of it is possible herefore Tt usc nose HTED TOBACCO OR AN OPEN FLAME OF ANY 98H51661 Fig 17 New Rear Throttle Body Water Hose 25 Install the fuel return hose 26 Check for fuel leakage NOTE If the vehicle has never overheat Due to the complexit that fuel hoses may have been loosened critical that this test be comple A Install fuel pressure gauge on See Fig 18 WARNING DO NOT SMOKE CARRY LIG TYPE WHEN WORKING ON OR NEAR A FUEL RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES ARE PRESENT AND MAY BE IGNITED RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 15 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell
562. regarding a front upper bushing noise Rubbing points Heat Shield Cross Section of Engine Mount 9559526 Fig 1 Cross Section of Engine Mount END OF ARTICLE OIL LEAK AT REAR STATIONARY GEAR O RING CAR FIX CAT B NO 003 98 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 35AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN OIL LEAK AT REAR STATIONARY GEAR O RING ON CAR REPLACEMENT PROCEDURE Model 5 1979 95 Mazda RX 7 Category B 01 Engine Bulletin No 003 98 Date July 16 1998 DESCRIPTION The following procedure is for on car rear stationary RS gear O ring replacement This procedure is not included in the Workshop Manual When the RS gear O ring is leaking use the following on car procedure REPAIR PROCEDURE 1 Verify customer complaint 2 Remove the flywheel M T or counterweight A T Refer to the Workshop Manual section C and H 3 Set the front rotor to TDC top dead center per the Work shop Manual section C 1 Remove the six bolts from the RS gear NOTE If the eccentric shaft and rotor are rotated with the RS gear removed they cannot be re used The engine will require overhauling 5 Insert two screwdrivers or pry bars and pry out the RS gear See Fig 1 CAUTION To prevent the RS gear from falling out loosely reinstall one of the bolts back i
563. resistance between 3 3 solenoid valve line 3 ground and terminal E of 2 3 pressure 2 3 solenoid valve line 3 3 If OK go to next step 3 pressure OK 3 3 Tf not OK repair wiring 3 3 Resistance 2 5 5 0 ohms 3 3 and or connector 3 3 i 3 No Replace solenoid valve 3 3 3 line pressure 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 3 Connect a dwell meter to 3 Yes Go to next step 3 terminals 1H and ground 2 3 3 as shown in Fig 14 7 3 3 Is output duty of dropping 3 3 3 3 resistor at EC AT control A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA unit OK 3No Replace EC AT control unit 3 Acceptable Dwell 2 3 perform road test and go to 3 Approx 5 Throttle 3 3 Step 8 3 valve fully open 2 3 3 3 Approx 100 Throttle 3 i 3 valve fully closed 3 2 2 6 Connect a dwell meter to 3 Yes Go to next step terminals 1F and ground 3 3 as shown in Fig 14 i 3 Is output duty of solenoid 3 3 valve line pressure at AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAKAAA 3 3 3 3 EC AT control unit OK 3 No Replace EC AT control unit Acceptable Dwell 3 perform road test and go to Approx 5 Throttle 2 3 Step 8 valve fully open 2 3 w w www iw WO
564. rminal 3D Under TEST CONDITIONS at idle TEST CONDITIONS should read Electrical cooling fan does not operate for an OFF condition and During electrical cooling fan operating for an ON condition PAGE F 174 TERMINAL 3M REMARK CORRECTION Page F 174 contains a correction involving ECU terminal pin voltage tests The terminal affected by the correction is listed below with the appropriate correction Terminal 3M Under REMARK at 2 6 2 8V reference REMARK should read Ignition switch ON measure the terminal voltage by using the digital type voltmeter END OF ARTICLE UNUSUAL NOISE FROM THE RIGHT ENGINE MOUNT CAT B NO 002 93 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 40AM MODIFIED ENGINE MOUNT R OLD ENGINE MOUNT R lt Clearance increased Clearance increased here here 94F52766 Fig 2 Modified Engine Mount Illustration Vehicles produced after the May 31 1992 production date come with the modified right engine mount Removal and installation procedures are outlined in appropriate service information PARTS INFORMATION TABLE AARAAAAAAARARAAAAAAAAAAARARAAAARAAAARARAAAAAARAAAAAARAAAARARAAAAAA 3 Part Number Description 7 Qty AARRARRARARARRARARARAARAARARARAARAARRAARAAAARARAARARAAARAAARARARAAR 3 FDOI 39 040C 3 Engine Mount R 3 1 3
565. ro Fro Fro Fro Labor Operatio t Brakes Dis Labor Operatio t Brakes Dis Labor Operatio t Brakes Dis Labor Operatio t Brakes Dis Labor Operatio t Brakes Pad Labor Operatio t Brakes Pad Labor Operatio 323 PROTEGE MX 3 929 Front Brakes Disc Plate s Fro Fro Fro Fro Fro Fro Fro Fro Fro Fro Fro Fro t Brakes Dis abor Operatio abor Operatio t Brakes Dis abor Operatio Labor Operatio t Brakes Dis Labor Operatio t Brakes Dis Labor Operatio t Brakes Pad abor Operatio abor Operatio t Brakes Pad Labor Operatio Labor Operatio t Brakes Dis Labor Operatio t Brakes Dis Labor Operatio t Brakes Dis Labor Operatio t Brakes Dis Labor Operatio t Brakes Pad Labor Operatio t Brakes Pad Labor Operatio n c P C c 8 8 c P C c s s n c P c 8 8 Plate s late s late s late s Plate s late s late s late s Plate s late s late s late s P0104 R amp R P0104 ARX 0 4 BRX 0 6 R amp R P0102ARX 0 6 R amp R P0208CRX 0 9 Machin hrs both sides hrs one side nrs both side nrs vehicl one sides P0113AMX 0 7 Machin on nrs vehicl PO on
566. ront amp back Roger 1B f 3 consists of front amp back systems 3 HFC 134A A C RECOVERY amp RECYCLING TRAINING EQUIPMENT CAT ST NO 008 95 Article Text p 9 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 R amp D Fountain Industries AM6000 Refrigerant Recovery ST100A 3 I Systems Inc 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAA Refrigerant Recovery 3 Fluoromizer 3000R FM3000R FM3000 3 Technologies Inc 3 with RM3 module Fluoromizer 3000 E 2 FM4000 12 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Refrigerant 3 RRC 1000 RRC 750 RRC 750X 3 3 Technologies Inc 3 RRC 751 TC 700 TX 600 3 3 2 AC 800 TX 200 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Refrigeration Transfer RFT 2212 RFT 2234 z 3 Systems Justice 3 3 3 Supply and Glass 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Rolo Inc 3 91R12 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Rotunda Ford 3 158 0000
567. ropriate container 34 Remove the bolts from the fresh air duct and remove the fresh air duct See Fig 24 Remove the rubber hoses from the air cleaner Remove the air cleaner installation bolts RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 19 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Air Cleaner Upper Radiator Hose 98E51668 Fig 24 Fresh Air Duct And Radiator Hose 35 Remove the upper radiator hose See Fig 24 36 Remove the alternator installation nuts from the alternator adjustor bracket to remove the tension control bolt See Fig 24 k X 3 Remove Bolts Remove Water Pump Pulley 98F51669 Fig 25 Tension Control Bolt And Water Pump Pulley 37 Remove the water pump pulley and the alternator belt See Fig 24 RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 20 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Loosen the four bolts from the water pump pulley Loosen the alternator belt Remove the bolts from the water pump pulley Move the belt and remove the water pump pulley 38 Remove the alternator adjustor bracket Remove the bolt attaching the alternator adjustor bracket to the wat
568. rough the Means system Part number N3A3 2341A Kink replace with modified hose part N3A3 20 341 A Vacuum Hose T C Relief Valve 95B52986 Fig 1 T C Relief Valve END OF ARTICLE LEFT ENGINE MOUNT INTERFERES WITH OIL PAN BOLT CAT B NO 008 97 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 35AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN LEFT ENGINE MOUNT INTERFERES WITH OIL PAN BOLT REMANUFACTURED ENGINE INSTALLATION Model s 1993 95 Mazda RX 7 Category B Engine Bulletin No 008 97 Date November 18 1997 VEHICLES AFFECTED 1993 95 RX 7 with a VIN of JM1FD333 80400027 and lower DESCRIPTION During remanufactured rotary engine installation the left rubber engine mount may interfere with an oil pan installation bolt To prevent this concern follow the procedures below INSTALLATION PROCEDURE 1 Verify concern 2 Remove oil pan bolt and discard See Fig 1 3 Apply silicone sealer to the bolt hole and pan area NOTE Three Bond TB1207D Loctite Ultra Gray 599 or equivalent 4 Install engine mounts according to section C of the workshop manual Tightening Torque 75 93 N m 7 6 9 5 Kgfm 55 68 ft lb 5 Operat ngine to normal temperature and inspect oil pan area for leaks If no leaks are present return vehicle to customer
569. rous The seat belt will not provide adequate protection and the user can be seriously injured in an accident Only use th xtender provided for you and for the particular vehicle and seat different vehicle or seat PARTS INFORMATION Never use an extender in a Seat belt extender availability application table for the different models is at Fig 2 NEVER USE When lap strap will not adjust snugly to hips When intersection of lap and upper torso straps measured along the lap strap is less than 6 inches from an imaginary center line of occupant s body NAVAJO and B SERIES 97H57528 SEAT BELT EXTENDER us Occupant Front Edge Of Do Not Use Extender Extender Buckle Unless it is physically required in order to wear the vehicle s safety belt If it causes the distance between the front edge of the extender buckle and the center of the occu pant s body to be less than 6 inches incorrect use of the extender may cause a serious injury Use extender only in the vehicle and seating position it was provided for Remove and stow when not in use by person it was provided for ALL OTHER MODELS Fig 1 Seat Belt Extender Warning Label SEAT BELT EXTENDERS DESCRIPTION ORDERING INFO CAT S NO 005 98 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 43PM 6198c
570. rt numbers ending in J1X are delivered in quantities 7 of 10 3 These vehicles ar quipped with Ford air conditioning systems 3 3 3 O Rings for these systems are supplied as a kit 3 3 3 3 P N ZZLO 61 J19 The kit contains 96 o rings 24 o rings each 3 of the sizes listed above and 24 3 4inch o rings Fig 1 Indicates where the o ring is measured to determine diameter and thickness Use this information and the chart above to identify he proper part if o rings are accidentally mixed 94C51948 Fig 1 O Ring Illustration For Diameter amp Thickness Measurement Fig 21 A C O RING REPLACEMENT GUIDE CAT U NO 001 94 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM 323 PROTEGE F HHH 94H52487 A 323 Protege Air Conditioning System Diagram A C O RING REPLACEMENT GUIDE CAT U NO 001 94 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM MX 3 94152488 A D Fig 3 MX 3 Air Conditioning System Diagram A C O RING REPL
571. rx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 07AM Approval Date 2 1 94 Minnesota Department of Transportation Central Services Building Central Shop Unit 6000 Minnehaha Avenue South St Paul Minnesota 612 725 2345 Approval Date 2 1 94 Potomac Electric Power Company 8400 B Old Marlboro Pike Upper Marlboro Maryland 20772 301 967 5294 Approval Date 8 12 92 Whayne Supply Company P O Box 35900 Louisville KY 40323 5900 502 774 4441 Approval Date 7 19 93 U S Army Ordinance Center and School Attn TP SB TSED C10 SFC Powell Aberdeen Proving Ground
572. s R amp R both sides Labor Operation P0204XRX 1 0 hrs REAR DISC BRAKES LABOR OPERATION TIME CODES 1993 1995 MODELS Millenia Rear Brakes Disc Plate s R amp R one side Labor Operation P0208ARX 0 3 hrs Rear Brakes Disc Plate s R amp R both sides Labor Operation PO208BRX 0 4 hrs Rear Brakes Disc Plate s Machine on vehicle one sides Labor Operation P0214AMX 0 7 hrs Rear Brakes Disc Plate s Machine on vehicle both sides Labor Operation PO214BMX 1 2 hrs Rear Brakes Pad s R amp R one sides Labor Operation P0209ARX 0 3 hrs Rear Brakes Pad s R amp R both sides Labor Operation PO214BRX 0 5 hrs VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 626 MX 6 Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Labor Operatio Labor Operatio RX 7 Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Labor Operatio Labor Operatio MX 5 Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Labor Operatio Labor Operatio MPV 1994 95 Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Disc Labor Operatio Rear Brakes Dis
573. s F0005XDX 3 0 9 3 3 Air Flow Sensor AFM Diagnosis 3 F0006XDX 3 0 4 3 3 Fuel Pump Diagnosis 1 F0007XDX 0 5 3 3 Charging System Diagnosis G0003XDX 3 1 4 7 3 NOTE Labor hours shown are the maximum allowable time Claim 3 only the actual time used for these operations AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU 3 END OF ARTICLE ETR OPERATION CASSETTE CHANGES BEFORE TAPE ENDS MT 0297 05 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 29PM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTUR
574. s If you DO NOT participate in the V4 0 reprogramming or miss the October 31 1997 cut off date your cost will be 313 32 plus shipping costs SHIPPING amp BILLING INFORMATION NEW V4 0 NGS CARD AND REPROGRAMMING OF V2 02 CARD CAT ST NO 004 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 39PM Your NGS card with V4 0 will be shipped to you by November 14 1997 DO NOT send payment to America Kowa Seiki Inc Your parts account will be billed for the appropriate amount Please contact your District Customer Support Manager America Kowa Seiki 800 824 9655 or 310 638 1000 or Tools Equipment Manager 714 442 6531 if you have any questions regarding this information REPROGRAMMING PROCEDURE Use the following procedure to have your Version 2 02 card updated to Version 4 0 1 Identify your card by using ballpoint pen or permanent marker and enter your dealer information See Fig 1 NOTE We recommend that you identify your card to ensure that you will receive the same card that you submitted for reprogramming 2 Carefully package your card and address it to the following address America Kowa Seiki Inc RE Mazda NGS Card Reprogramming 20013 S Rancho Way Rancho Dominguez CA 90220 3 Send your package prepaid Your dealer is responsible for shipping costs Be sur
575. s 3 U U 3 www 0 Check M Tips On Line or Call Hotline AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM U AAAAAAAAAAAAAAAAAAAAAA NO 3 Can Trans Be Repaired AAAAAAAAAAAAA Complete A T Check 3 3 At Dealer 3 3 Sheet Request Auth 3 U orization Order Trans 3 YES 3 Replace Trans 3 3 U 3 Repair Use WSM Refer to the Warranty Repair Guide AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU AR AAAAAAAAAAAAAAAAAAA NO AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA A 3 Is Vehicle Repaired AAAAAAA Check M Tips On Line or Call Hotline
576. s bulletin describes Conditions that may lead to battery failure Correct inspection and servicing procedures Samples of current inspection sheets and maintenance records Requirements for Warranty Submission X CONDITIONS LEADING TO BATTERY PROBLEMS If a customer complains of poor battery performance i e slow start no start perform the following quick checks prior to detailed diagnosis or parts replacement BATTERY PROBLEMS TABLE UAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAABAAAAAAAAAAAAAAAAAAAAAAAAA P Item Check AAAAAAAAAAAAKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAARAAAAAAAAAA 3 Condition Prior To Battery Door open lights left on radio on 3 Problem 3 etc 3 Vehicle Condition 3 Add on accessories installed 3 3 properly alarms cellular phones 3 3 z stereo amp etc 3 Battery Condition 3 Correct fluid level Check 3 3 Indicator Eye if equipped and 3 note color 3
577. s or failures Therefore please complete the necessary work for all new and used vehicles in your inventory prior to sale or lease Please make certain that the appropriate personnel in your dealership are familiar with the details of this Recall Campaign for responding to customer inquiries Should you have any questions please contact your District Customer Support Manager We apologize for any inconvenience this program may cause you and your personnel Your understanding and support in carrying out this campaign will be greatly appreciated Sincerely Mazda Motor of America Inc CONDITION OF CONCERN If an RX 7 has been subjected to high speed operation and then parked before cooling down the residual engine heat combined with the build up of pressure in the cooling system can raise the temperatur of the coolant to levels where the integrity of the cooling system can be compromised Repeated operation of the vehicle in this manner may produce cooling system leaks Under some circumstances the leaking coolant mixture can collect on the top of th ngine where some of the water can evaporate increasing the concentration of the coolant If coolant then leaks onto the exhaust manifold an engine compartment fire could be the result SUBJECT VEHICLES TABLE UAAAKAAAAAAAAAAAAAAAAAAAABAAAAAAAAAAAAAAAAAAAAAAAAAAAAL 3 Model Year amp Model VIN Ra
578. scription Qty 3 FDY1 56 788 3 Washer 5 2 3 NOTE If the hood is replaced with a modified part the washers do not need to be installed WARRANTY INFORMATION Applies to Vehicles Covered Under Warranty Warranty Type Code A Customer Comment Code 82 Damage Code 99 Part No of Main Cause FDY1 56 788 Operation No XX0523RX Labor Hours 052 Hrs END OF ARTICLE STATIC ELECTRICTY BUILDUP SOLUTIONS MT 1095 11 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 41AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN STATIC ELECTRICITY Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 1095 11 Date 1995 DESCRIPTION Sometimes customers may feel a static shock when getting out of the vehicle This shock is the result of static electricity build up This phenomenon occurs more frequently in the winter season or in dry weather The following two procedures ar ffective in preventing static shock Please suggest these methods to your customers 1 Touching a metal panel while exiting the vehicle is a very effective way to eliminate static shock After opening the door touch or hold on to
579. se a multi tester with the accuracy equivalent of a FLUK 70 Series The following models have air flow meters with measuring plates and should be diagnosed using the method listed below 1986 89 323 1990 93 323 Protege 1990 92 626 MX 6 1990 91 929 1988 93 MPV 1990 93 MX 5 1993 MX 3 1 6 Litre 1 Check for smooth movement of the measuring plate see Fig 5 If no problem is found reinstall the air flow meter ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM 94J53032 Fig 5 Checking Air Flow Meter Door 2 If no problem is found in the Hotline for assistance AIR FLOW METER CHECK SHEET Dealer Name Vehicle Year Model Repair Date 1 Customer Complaint ileage air flow meter contact the Technical Technician Number M T A T VIN Repair Order Number 2 Was the customer s complaint verified Yes No 3 Reason for replacement Air Flow Meter Out Of Specification Yes No UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Measurement 3 Factory Specifications 3 AARAAAAAAAAAAAAAAAAAAAAAAAAAABAAAABAAAABAAAAAAAAAAAAAAABAAAAAAAAA 3 Intake Air 3 3 Temperature Sensor 3
580. sible INSPECTING OIL LINES amp CLAMPS Be sure to i pinched cra problem exists replace it CAUTION Alwa BACK FLUSHING 1 Using the P nspect the lines hoses pipes for cuts crimps cks or any other damage before reusing them If any or the hose comes off when applying oil pressure ys use new clamps when replacing hoses ower Flushing Equipment manufacturer s instructions connect equ DIRECTION o ipment so the flushing fluid flows in the OPPOSITE f normal fluid flow See typical example of back flushing fl ow in Fig 2 AUTOMATIC TRANS COOLER LINE FLUSHING PROCEDURE CAT K NO 005 98 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 23AM 2 Flush oil cooler lines until discharge fluid is clean CAUTION If the cooler can not be properly flushed using recommended equipment send the radiator out for sublet cleaning or replace NOTE Refer to the WSM or Automatic Transmission Quick Reference Guide P N 9999 954501 96 for exact location of cooler line inlet outlet fittings FORWARD FLUSHING 3 Connect power flushing equipment so the flushing fluid flows in the direction of normal fluid flow See typical example of forward flushing flow in Fig 3 4 Flush oil cooler lines until DISCHARGE FL
581. spect This Area For Damaged Threads 94B52283 Fig 1 Inspect for Damaged Threads 95 If stitching is damaged seat belt replacement is necessary If the SEAT BELT CAUTION LABEL EXPOSED INSPECT REPLACE CAT S NO 001 94 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 40AM stitching is not damaged the seat belt caution label cover should be stitched in place NOTE If the seat belt was damaged as result of an accident the replacement is not a warrantable item SLEEVE SEWING PROCEDURE 1 Fold the seat belt fuse over the caution label as shown in Fig 2 2 Slide the sleeve over the seat belt fuse Fuse Should Be Even With Line Pull Slesve Up And Over Fuse 94652284 Fold Fuse Over Label Fig 2 Folding Seat Belt Fuse Over Caution Label 3 Sew the sleeve in place as shown in Fig 3 ETO NOTE SEAT BELT CAUTION LABEL EXPOSED INSPECT REPLACE CAT S NO 001 94 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 40AM 3 8mm 5 10mm Pull Thread Through Knot And Cut Excess 94D52285 Sewing Sleeve in Place The sleeve should be sewn above the seat WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty Warranty Type A Customer Comment Code
582. ssurize the system to more than 142 kPa 1 45 kgf cm 20 6 psi WARNING Be careful to avoid injury from escaping steam or hot water when removing the radiator cap WORKSHOP MANUAL CORRECTION FUEL SYSTEM CAT W NO 040 92 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 40AM GR eR LNA y 94D55494 Fig 1 Pressurizing the Cooling System PAGE F 67 SELF DIAGNOSIS CHECKER CHART CORRECTION Switch Monitor Function Individual switches can be inspected by the SST Self Diagnosis Checker or DT S1000 NOTE The TEN terminal of the diagnostic connector must be grounded and the ignition switch ON engine stopped If either switch remains activated the monitor lamp will be illuminated NEUTRAL SWITCH MT CLUTCH SWITCH MT INHIBITOR SWITCH AT DIAGNOSIS SYSTEM A C SWITCH KNOCK SENSOR HEADLIGHT SWITCH BLOWER CONTROL SWITCH REAR WINDOW DEFROSTER aoe TEST MODE 94E55495 Fig 2 ECU Logic Circuit LOGIC TABLE UAAAKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAG Switch 3 Self Diagnosis Remarks 3 3 Checker Monitor temp 3 3 AAAAAAAAAAAAAAAAAAAAAAAA 3 SELF DIAGNOSIS CONNECTOR SELECTOR MONITOR LAMP WORKSHOP MANUAL CORRECTION FUEL SYSTEM CAT W NO 040 92 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchel
583. st and white grease test Verify repair 976G58632 1 Card Test WIND NOISE AROUND DOORS CAT S NO 018 98 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 44AM GREASE PATTERN 97H58633 Fig 2 Grease Pattern Measur OUTLINING 97158634 Fig 3 Hinge Mount Outline END OF ARTICLE WIND NOISE FROM THE DOOR WINDOW NEW GLASS GLIDES CAT S NO 002 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 44AM ARTICLE BEGINNING TECHNICAL S ERVICE BULLETIN WIND NOISE FROM THE DOOR WINDOWS Model s Category Bulletin No Date DESCRIPTION Some vehicl windows ne entering th fit flush a REPAIR INFO Inspect th 1993 Mazda RX 7 with a VIN of JM1FD3 P02057080 or lower produced through April 30 1992 S Body 2i 002 93 2 5 93 es may experience a wind noise from the right and left door ar the outside door handles This noise is due to air e cabin area When completely rolled up the windows do not gainst the glass channel RMATION vehicle for excessive clearance s Fig 1 If the above condition e part see Fi sliding res modificatio Removal and service inf xists replace the affected glass guide s with a modified g 2 The glass guide
584. stimated cost for assembly replacement Cost includes A Replacement Part B SRT or Dealership Labor Rate if applicable C Sublet description and cost if applicable Dealerships can fax the ATDS to MASH at 714 442 6598 The MASH specialist will contact the dealer regarding the fax request 4 The Hotline specialist will review the request and determine if Additional repair information will eliminate the need for complete assembly replacement If this is determined the dealer will be requested to perform additional steps to repair the vehicle In this circumstance no authorization number is issued Complete assembly replacement is the best alternative In this circumstance an authorization number is issued for warranty reimbursement HOTLINE HOURS AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 14 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM Operation hours are 9 a m to 4 p m for each continental time zone Monday through Friday 9 a m to 3 p m in Hawaii Fax transmission is available 24 hours a day seven days a week Responses to fax will occur during regular business hours TRANSMISSION ORDERING INFORMATION If the vehicle is within warranty MASH authorization must be obtained before ordering a transmission for replacement under normal war
585. sure th i remaining front rotor thickness and run out Determine machining 0 8 mm sufficient rotor material remains to allow Limit Stated minimum thickness for the model plus e If machining can be achieved an on car brake lathe is recommended and will be required for all warranty repairs after January 1 1995 to ensure a precise rotor surface NOTE After machining rotor s with an on car brake lathe you must remove all metal cuttings particles from the ABS toothed ring the reluctor and the ABS sensor Failure to remove these particles will prevent proper function of the ABS system f If machining can not be achieved due to rotor thickness limitations the dealer should replace the rotor To ensure a successful repair run out and or DTV must be removed by on car machining even on new rotor s g Install the wheel in the same location relative to the hub as it was originally positioned h Torque wheel lug nuts to the specifications in the service manual Dal Test driv the vehicle to confirm repair gs If the brake judder is still felt correct the rear rotor s using steps ON through i VIBRATION PULSATION WHILE BRAKING PROCEDURE CAT P NO 001 95 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 26AM
586. sy reference the following list of Fusible Links have been compiled FUSIBLE LINK REFERENCE CHART Year Model Location P N 1979 82 626 Engine Compartment 8174 66 760B 1983 85 626 Gas Engine Compartment 3775 67 099 1983 85 626 Diesel Engine Compartment H047 67 099 1983 85 626 Alternator 67 67 099 1979 RX 7 Under Dash 1175 66 710A 1980 RX 7 Under Dash 8130 66 710 1980 RX 7 Engine Compartment 8341 18 055 98 RX 7 Under Dash FA02 67 099 981 85 RX 7 Engine Compartment 3777 67 099 981 85 RX 7 Transmission 8341 18 055 981 85 RX 7 Engine Compartment 8871 67 099 1984 85 RX 7 Engine Compartment 3775 67 099 981 85 LC Engine Compartment B003 67 099 981 85 LC Engine Compartment B005 67 099 981 85 LC Engine Compartment 006 67 099 1977 82 B2000 Engine Compartment 094 67 099 1983 84 B2000 B2200 Engine Compartment UA47 66 099 1988 93 MX 6 Engine Compartment FB01 67 099 M T Non Turbo A T 1988 93 626 Sedan Engine Compartment FB01 67 099 1988 93 626 Hatchback Engine Compartment F
587. system memory back up circuits and other electrical devices The maximum voltage for vehicle electrical components is approximately 15 volts Battery chargers generate at least 15 volts and in some cases as much as 20 volts Damage may also occur to power window switches lights and other similar components that are activated or that are in use while the battery is being charged in a vehicle with the battery cables connected Be sure to apply the above caution when attempting to charge a battery NOTE Removing battery cables will erase memory circuits for audio PCM and other devices in the vehicle 98154153 Fig 1 Battery Charger END OF ARTICLE ART BATTERY RECHARGING DISCONNECT NEGATIVE TERMINAL MT 08 10 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 25PM ICLE BEGINNING TECHNICAL SERVICE BULLETIN BATTERY RECHARGING Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 08 10 Date 1995 DESCRIPTION Always disconnect the negative cable from the battery before connecting a battery charger to it Leaving the negative cable connected could damage the control unit or cause the air bag to inflate as the battery recharges END OF ARTICLE DTC DIAGNOSTIC TROUBLE SHOOTING TIPS MT 0597 07 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mi
588. t 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM Warranty Customer Pay Signature Date heck sheet must be returned with the replaced part to ervicing PDC R OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER RARARAAAAAAARA Diagnostics AARARARAARARARAARA RARAAAARARAAAARA U 3 MMA 3 UAAAAAAAAAAAAAAAAY 3 Results AA No Trouble A Contact Region AAA Found 3 Hot Line 3 3 AAAAAAKAAAAAAAAAAU gt Trouble Found d 3 3 3 3 AAAAAAAAAAAAAAAA 3 Complete 3 Hot Line 3 Check Sheet Instruction 3 3 Orden papt 5 Authorized AAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAU Replacement 3 Auth No Required UAAAAAAAAAAAAAAAAAAA Review Receive Parts 3 Diagnostics AAAAAAAAAAAAAAAAAAAAU 3 UAAAAAAAAAAAAAAAAAAAY Attach Copy Of 3 Check Sheet To 3 R O 3 A AAAAAAAAAAAAAAAAAAU 3 AAAAAAAAAAAAAAAAAARA 3 Warranty Claim 3 Application SECTION 2 AIR FLOW METER DIAGNOSTIC PROCEDURES NOTE Procedures listed below do not apply to the following model year vehicles 1988 92 B2600 1989 90 RX 7 up to and i
589. t Repair Procedure The subject vehicles of Recall No 60504 Fuel Leakage could also be subject to Recall No 54407 Coolant Leakage which was launched in July 1994 When the subject vehicles are brought in for repair please check if recall campaign No 54407 has been performed If not please perform recall No 54407 in addition to No 60504 based on the Repair Procedures found flow chart on the following page Please follow the flow chart to determine which procedure to perform before beginning repairs on each vehicle SUBJECT VIN RANGE TABLE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Fuel Leakage 1993 JM1FD33 PO200001 210660 3 3 1994 95 JM1FD33 R0300001 S0400026 3 Coolant Leak 1993 94 JM1FD33 PO200001 R0302076 RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM 3 Can be replaced by any letter or number 3
590. t SST Engine Signal Monitor And Adapter as shown in Fig 1 Place application panel sheet on the Engine Signal Monitor ECU Application Panel Sheet 94153028 Engine Signal Monitor Fig 1 Engine Signal Monitor and ECU 3 Measure the voltage according to the specifications in the appropriate service information 4 If the voltage is different than specified check the related input and output devises and wiring for damage If no problem is found and the reading remains out of specification replace the ECU 5 If the voltage is within specification and the problem still exists contact the Technical Hotline for assistance CAUTION Terminals A amp B are for external voltmeter connections Use these terminal to attach a digital voltmeter or oscilloscope for precise volt readings See Fig 2 for illustration Never apply current to these terminals damage to the ECU will result ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM Terminals A and B 94E53029 Fig 2 Engine Signal Monitor ECU CHECK SHEET Dealer Name Technician Number Vehicle Year Model M T A T VIN Repair Date _ Mileage Repair Order Number 1 Customer Complaint 2 Was the customer s complaint verified Yes No
591. t battery failed 6 months ago WARRANTY INFORMATION TABLE EXAMPLE 2 Claim Submission 3 Dealer Reimbursement 3 AAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAANAAARAAAAAAARAAABARARAAAR Warranty type P Warranty labor rate 50 00 hr 3 3 3 3 3 3 Symptom code 20 3 3 3 Damage code 81 3 3 Vendor code KN999 3 3 3 Part number 3 3 7 main cause 5555 95 BATT 3 Quantity 1 must enter 3 3 quantity of one 3 3 Pro Rate 100 3 15 70 handling charges 3 3 3 only 3 3 Related part s 0 wet battery acid 3 3 3 3 3 3 3 is not required Labor operation G0501ACX WARRANTY BULLETIN MAZDA BATTERY WARRANTY CAT G NO 1 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 47PM 3 Labor Hours 0 5 3 25 00 3 3 3 Total 3 3 3 reimbursement 40 70 AR AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAA 3 CUSTOMER S RESPONSIBILITY 00 00 3 U Free battery provided by Interstate Distributor Example 3 A customer purchased a battery over the counter
592. t temperature is below 800C 1769 F 2 Turn the ignition switch to ON for 15 seconds or longer 3 Turn the ignition switch to OFF 4 Ground the check connector by using a jumper wire 5 Turn the ignition switch to ON and verify that the cooling fan operates approximately 100 150 seconds after the ignition switch is turned to ON 6 If the cooling fan will not operate inspect the following Battery positive voltage Fan control signal Engine coolant temperature signal Ground SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 19 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 39AM 7 Turn the ignition switch to OFF 8 Verify that the cooling fan keep operating after the ignition switch is turned to OFF 9 If not replace the cooling fan control module See Fig 5 10 Wait for approximately 20 seconds 11 Disconnect cooling fan relay connector A Verify that the cooling fan operates at low speed See Fig 6 12 If not inspect the cooling fan relay 13 Connect cooling fan relay connector A Verify that the cooling fan operates at the speed before connector A is disconnected 14 Disconnect the jumper wire from the check connector Verify that the cooling fan operates at low speed 15 Turn the ign
593. t wipers don t work you may not need to replace the wiper motor The wipers may only be temporarily disabled Here s why A wiper motor circuit breaker deactivates the wipers for about five minutes if it senses an overload like heavy snow build up on the windshield It s a fail safe designed to prevent wiper damage After the short period the wipers will start working again END OF ARTICLE FRONT WIPER MOTOR OPERATION INSPECTION CAT 15 NO 070 88 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 31PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN WIPER MOTOR INOPERATIVE CIRCUIT BREAKER ACTIVATION Model s All Mazda Vehicles Except B Series amp Navajo Category T Body Electrical System Bulletin No 013 97 Date June 19 1997 NOTE This bulletin supersedes Technical Service Bulletin Category 15 070 88 and Category G 003 97 dated May 19 1997 DESCRIPTION The wiper motor is equipped with a built in circuit breaker to protect the circuit and motor from over heating due to motor overloading See Fig 1 Overload may occur when Motor temperature exceeds 150 degrees C 302 degrees F Wipers are frozen to the windshield Wiper motion is restricted due to heavy loads snow or mud build up NOTE Circuit automatically resets when motor temperature decreases below 90 degr
594. tain chemicals alcohol or methanol that erode metal parts Service Managers should inform customers that Mazda does not recommend reconditioned anti freeze and that problems mechanical and otherwise related to the use of reconditioned anti freeze are not warrantable CAUTION Antifreeze is considered a hazardous and toxic substance Handled and disposed must be done in accordance with local state and federal laws END OF ARTICLE ARTICLE BEGINNING REVISED ROTORY ENGINE PRICING CAT RF NO 95 24 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM TECHNICAL SERVICE BULLETIN REVISED ROTARY ENGINE PRICING Model 5 Category Bulletin No Date DESCRIPTION The price of the Rebuilt Rotary Engines has changed of 600 00 is now included in the dealer Price 1995 INFORMATION TABLE These new prices wer List or the DMS tapes The next issue of November prices PARTS INFORMATION ffectiv All Mazda RX 7 Models Parts Flash RF 95 24 October 20 The PARTS INFORMATION TABLE 3 Part Number 7 Year Model 3 A core charge Refer to the PARTS 10 2 95 and are not re
595. tall Retaining Bracket 94A59907 Fig 2 Installing Retaining Bracket Install differential side gear holders Install Diff Side Gear Holders On Both Sides 94859908 Fig 3 Install Differential Side Gear Holders AUTOMATIC TRANSMISSION FLUSHING EQUIPMENT The automatic transmission oil AUTOMATIC TRANSMISSION REPAIR POLICY CAT K NO 002 95 Article Text p 17 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 24AM cooler must be flushed whenever performing a major transmission repair or replacement If the cooler is not flushed properly residual become dislodged and affect the new transmission s operation A labor opera friction material and metal may equipment If the transmission oil tion is established to cover the use of flushing cooler is not flushed with the proper flushing equipment prior to repair completion and a comeback repair occurs due to clogged oil cooler circuits the repair cost is not warrantable RECOMMENDED m MANUPAGTURERS E i de UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARA 3 Manufacturer Telephone Number 3 Kent Moore 800 345 2233 3 3 3 3 OTC 80
596. tchell Repair Information Company LLC Saturday August 25 2001 07 34AM WARRANTY INFORMATION Applies to Vehicles Covered Under Warranty Warranty Type Code A Customer Comment Code 92 Damage Code 99 Part No of Main Cause FDO1 69 44XB 00 Operation No XX0552RX Labor Hours 0 4 Hrs END OF ARTICLE DIRT ON SEAT BELT AND ANCHOR CAT S NO 028 96 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 34AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN DIRT ON SEAT BELT AND ANCHOR Model s A l Mazda Models except Navajo and B Series Category S Body Bulletin No 028 96 Date June 27 1996 DESCRIPTION Dirt accumulating on the seat belt anchor or webbing may restrict seat belt travel over the anchor This may cause some customers to complain that the seat belt will not retract or requires effort to pull out Customers with this concern should have the belt inspected and serviced according to this bulletin SERVICE PROCEDURE 1 Clean the seat belt contact area and sash guide NOTE Use a brush or cloth lukewarm water and neutral detergent CAUTION Do no affect use volatile solvent for cleaning this substance may the seat belt strength 2 Verify seat belt operation If the seat belt is not operating smoothly refer to the workshop manual for troubleshooting procedur
597. tchell Repair Information Company LLC Sunday August 19 2001 01 26PM ARTICLE BEGINNING TECHNICAL INFORMATION TIP MANUFACTURER DTC DIAGNOSTICS Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0597 07 Date May 1997 DESCRIPTION The diagnostic procedures for DTCs Diagnostic Trouble Codes in the Workshop manual don t always include the procedure to check related connectors that are within the DTC component s circuit Whenever performing diagnostic procedures always use the wiring diagram in conjunction with the Workshop Manual Check each related connector for the following Incomplete connection Loos ma terminals Terminals that are pushed out of their connectors Water inside the connector Terminal corrosion Also check each related harness for damage END OF ARTICLE ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN DIAGNOSTIC PROCEDURES FOR ECU S AIR FLOW METERS FUEL PUMPS AND ALTERNATORS Model 5 Category Category 1988 94 Mazda Vehicles G Engine Electrical G Engine E except Navajo and 1994 B Series No 002 93 Date 9 16 93 Now 93 03 Date Oct 93 ilectrical DESCRI
598. te Antenna Leads not removeable d 1 Pin Ground 94B54008 c 13 Pin DIN Fig 6 Rear View of Radio 12 Pull the radio straight out Make sure that you carefully feed the antenna leads through the radio opening as you pull out the radio See Fig 7 RADIO REMOVAL TIPS W CD PLAYER CAT T NO 018 92 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 42PM 94C54009 Fig 7 Radio Removal END OF ARTICLE REAR WINDOW DEFROSTER GRID LINE REPAIR PROCEDURE CAT T NO 015 95 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 42PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN REAR WINDOW DEFROSTER GRID LINE REPAIR Model 5 All Mazda Models Category T Body Electrical System Bulletin No 015 95 Date Issued November 14 1995 Date Revised December 21 995 DESCRIPTION The following procedure should be used to repair broken grid lines on rear window defrosters Place a copy of these procedures in the appropriate section of the workshop manual REPAIR PROCEDURE 1 Turn the defroster switch on with the ignition in the on position 2 Determine the broken grid line visually or with a test light or voltage meter 3 Turn the defroster and ignition Off 4 Cle
599. te November 24 1995 DESCRIPTION A new law by the United States Environmental Protection Agency EPA requires all who work with and make A C repairs to have Technicians trained and certified by an EPA approved organization EPA approved HFC 134a recovery recycling or recover only equipment These requirements becam ffective November 15 1995 To become more familiar with this new law review the EPA fact sheet RECYCLING REFRIGERANT FROM MOTOR VEHICLE AIR CONDITIONERS It further explains this law and addresses some general concerns For your convenience the LIST OF APPROVED SECTION 609 CERTIFYING ORGANIZATIONS a f nd APPROVED REFRIGERANT RECOVERY RECYCLE EQUIPMENT referenced in the act sheet are also included RECYCLING REFRIGERANT FROM MOTOR VEHICLE AIR CONDITIONERS A regulation signed in July 1992 by the administrator of the United States Environmental Protection Agency EPA requires that motor vehicle air conditioning refrigerant be recycled This fact sheet will help you become familiar with this law and address some of your concerns OUR THREATENED OZONE LAYER The stratospheric ozone layer shields the earth from harmful ultraviolet UV radiation
600. tests 7 158 contains two corrections involving ECU terminal pin voltage Ihe terminals affected by the correction are listed below with the appropriate correction Terminal 2K WORKSHOP MANUAL CORRECTION FUEL SYSTEM CAT W NO 040 92 Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 40AM Under TEST CONDITIONS at battery voltage TEST CONDITIONS should read Ist and 2nd position Terminal 3D Under TEST CONDITIONS at idle TEST CONDITIONS should read Electrical cooling fan does not operate for battery voltage and During electrical cooling fan operating when voltage is below 1 0V PAGE F 160 TERMINAL 3M REMARK CORRECTION Page F 160 contains a correction involving ECU terminal pin voltage tests The terminal affected by the correction is listed below with the appropriate correction Terminal 3M Under REMARK at 2 6 2 8V reference REMARK should read Ignition switch ON measure the terminal voltage by using the digital type voltmeter PAGE F 172 TERMINAL 3D TEST CONDITION CORRECTION Page F 172 contains two corrections involving ECU terminal pin voltage tests The terminals affected by the correction are listed below with the appropriate correction Terminal 2K Under TEST CONDITIONS for an ON condition TEST CONDITIONS should read Ist and 2nd position Te
601. the connector bolts Tightening Torque 240 360 kgf cm 208 312 in lbf Use new gaskets Gasket N236 13 483 x 2lpcs RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 39 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM Reuse the connector bolts Gasket 94159335 Fig 56 Installation of Fuel Hose on Secondary Fuel Distributor 29 Replace the fuel hose on the return side of the secondary fuel distributor with a new one S Fig 57 NOTE Replace the clip also with a new one Do not use clips other than those included part number below Fuel hose N370 13 415 Clip 8574 13 157 For the direction of the clip claws see Fig 57 Do not place the clip on the pipe on the bulge 94159336 Fig 57 Return Side of Secondary Fuel Distributor Hose Replacement Place the Clip Claw on the Top Use New Parts RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN CAT RC NO 95 01 Article Text p 40 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 38AM 30 Replace the two vacuum tubes with new ones S Figs 58 Vacuum tube 99351 04150 x 2 pcs 94A59337 Fig 58 Location of Vacuum Tubes 31 Install the primary fuel
602. the rear rotor s using steps C through I SERVICE TOOLS The Accu Turn model 8750 On Car Brake Lathe is recommended by Mazda The brake lathe is available through Mazda Canada s Equipment Program at 1 800 33 6687 WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty Warranty Type O Symptom Code 83 Damage Code 9B Part Number Main Cause 33 25 FREE 26 25 Rear ot Vehicl Rear Wheel Drive Only Operation Number P0113AMX 0 7 hrs Front One Side PO113BMX 1 2 hrs Front Both Sides P0214AMX 0 7 hrs Rear One Side P0O214BMX 1 2 hrs Rear Both Sides NOTE 1 Unnecessary replacement of rotors will result in warranty claim denial 2 Brake pad replacement costs will not be warrantable for brake judder repair 3 The 1995 SRT Microfiche for the MX 3 RX 7 929 MPV Miata etc shows labor times for on car rotor machining are 0 7 hrs Max for one side and 1 2 hrs Max for both sides 4 If an Accu Turn on car lathe is used apply the labor time from the table above If an off car lathe is used refer to the labor times from the 1994 SRT The next issue of the SRT microfiche will be revised to show the new labor times 5 Please refer to the attached sheet for all valid off car brake and on car brake machining operation codes for all models and model years END OF ARTICLE RATTLING FROM DASHBOARD AT IDLE W B
603. the workshop manual If the leak is determined to be coming from the power steering gear follow the procedures listed below NOTE Service Managers should place a copy of this bulletin in section N of the workshop manual INSPECTION PROCEDURE 1 Check the color of the fluid that is leaking See Fig 1 If the fluid is red proceed to step 3 If the fluid is any color other than red i e yellow colorless this is grease and no problem exists with the power steering gear Proceed to step 2 2 Inspect the boot for damage i e cracks or tears 3 Remove the boot wire and inspect the inside of the boot for contamination dirt water etc See Fig 1 Tf there is a large quantity of red fluid inside the boot this indicates insufficient sealing Replace the side seal and the power steering gear according to section N of the workshop manual See Fig 1 If a minimal quantity of red fluid is present proceed to step 4 4 Start the engine and turn the steering wheel right and left lock to lock Tf the fluid is leaking replace the side seal and the power steering gear according to section N of the workshop manual If no fluid is leaking no problem exists in the power steering CHECKING PROCEDURE FOR POWER STEERING BOOT LEAKAGE CAT N NO 004 97 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 19
604. ticle Text p 21 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM the ground terminal See Fig 28 3 Pinch the fuel return hose with a suitable tool to stop any fuel return to the tank See Fig 29 NOTE Use a dull edged SST so that it does not damage the hose 4 Operate the fuel pump for more than five minutes and check for fuel leakage Check for fuel leakage visually and by odor Carefully check the positions seven indicated by the arrows shown in Fig 29 f fuel leakage is found repair the problem Once repaired check again according to the above steps Diagnostic Connector To round Terminal 94G59341 Fig 28 Diagnostic Connector to Ground Terminal RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 22 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 55AM Pinch here to prevent fuel return ep 94H59342 Fig 29 Seven Fuel Leakage Areas 34 Install the vacuum pipe assembly See Fig 30 Replace the vacuum tubes 4 5 6 7 10 and 11 with new ones 2 Connect the hoses 3 14 to the vacuum pipe assembly 3 Connect the coupler of each solenoid valve 4 Install the vacuum pipes to the engine by tightening the
605. till less than 13 5V replace the alternator CAUTION Diagnostic procedures for lead acid battery performance are different than those used for maintenance fr batteries lithium hybrid type Incorrect diagnosis will result in false readings and unnecessary battery replacement if the wrong procedure is followed Diagnostic procedures used for testing lead acid batteries provide false readings leading to unnecessary replacement if used on maint provided EG batteries The information flow chart below is nanc or diagnosing maintenance fr batteries BATTERY DIAGNOSTIC PROCEDURES FLOW CHART 1 UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Measur 3 the open circuit voltage of the battery with a digital volt meter capable of reading 0 01V 3 U AAAAAAAAAAAAAAAAA NO 3 Battery Voltage AAAAAAAAAAA Quick Charge Battery And 3 12 4V or Above 3 3 Recheck Voltage see NOTE 3
606. to your Body Shop Personnel END OF ARTICLE SEAT BELT CAUTION LABEL EXPOSED INSPECT REPLACE CAT S NO 001 94 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 40AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SEAT BELT CAUTION LABEL COVER Model 5 1993 Mazda RX 7 1994 Mazda RX 7 VIN of JM1FD333 R0300001 through JM1FD333 R0301350 1993 Mazda MX 5 Miata 1994 Mazda MX 5 Miata VIN of JM1NA353 R0500001 through JM1NA353 R0506949 Category S Bulletin No 001 94 Date 1 5 94 i NOTE The asterisk in the VIN can be any number 0 9 or X DESCRIPTION If the sleeve covering the seat belt label has dropped the caution label becomes exposed If this is found the seat belt should be nspected as described below to determine if replacement is necessary f the seat belt is not damaged the sleeve should be sewn in place according to the instructions in this bulletin NOTE It is important that the sleeve be sewn correctly If the repair is being performed by an outside upholsterer provide the instructions in this bulletin SEAT BELT INSPECTION PROCEDURE Ts 2 Slide the sleeve down to expose the fuse portion of the seat belt Inspect the area for frayed or broken stitching See Fig 1 Label Fuse In
607. tor coolant pressure has dropped locate the leak and repair as necessary Retest after repair following the above procedures After confirmation that no leaks are present remove the tape from the overflow hole and install the pressure cap 60 Affix the Campaign Label number 54407 and number 60504 onto the driver s side door for future confirmation that the campaign has been completed on this vehicle S Fig 74 Recall Label 54407 and 60504 94F 59357 Fig 74 Recall Label 54407 amp 60504 Identification WARRANTY INFORMATION REPAIR CONTENT FUEL HOSE AND COOLING SYSTEM WARRANTY TABLE 3 With Coolant Without Coolant 3 Fuel Hose d 3 3 Leak 2 Leak 3 3 EAE ASS SR AR 3 Warranty Type 7 s 5 RRAAARAARAARKAAAAAAAAAARARARAAARAAARAAARAAARAAAAAAAAAAARARARAARAAAAA 3 Recall No 3 60504 3 60504 3 60504 E a 5 3 Process Code 3 3 3 3 AAAARAAAAAAAAAAAAARARAAAAAAAARARAAARARAARAAAAARAAAARARAAARARAAARARAA RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 54 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 3 Labor Hours 3 4 6 Hrs 3 3 2 Hrs 2 4 Hrs 3
608. tre 1 Check for smooth movement of the measuring plate see Fig 5 If no problem is found reinstall the air flow meter ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 27PM 94J53032 Fig 5 Checking Air Flow Meter Door 2 If no problem is found in the Hotline for assistance AIR FLOW METER CHECK SHEET Dealer Name Vehicle Year Model Repair Date 1 Customer Complaint ileage air flow meter contact the Technical Technician Number M T A T VIN Repair Order Number 2 Was the customer s complaint verified Yes No 3 Reason for replacement Air Flow Meter Out Of Specification Yes No UAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Measurement 3 Factory Specifications 3 AARAAAAAAAAAAAAAAAAAAAAAAAAAABAAAABAAAABAAAAAAAAAAAAAAABAAAAAAAAA 3 Intake Air 3 3 Temperature Sensor 3 3 Base Resistance 3 E2 VC 3 3 3 3 3 3 3 3
609. trol Solenoid Valve Solenoid Valve White Charge Control Brown Turbo Control 98D51618 l Intake System Schematic RARARARARARARARAAAAAARARARARARARARARAAAAARARARARARARARAAA A gt Item Description Part 1 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA SERVICE TIPS FOR PERFORMING RX 7 FUEL LINE RECALL CAT AD NO 002 96 Article Text p 8 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 44PM A 3 Check Valve Positive Pressure N390 13 995A 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 B 3 Check Valve Positive Pressure N390 13 995A 3 AR AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 e Vacuum Hos Pressure Chamber N3A1 20 341 3 3 3 Exit 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 D E Vacuum Hos Pressure Chamber N3A1 20 342 E 3 Entrance 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 E i Vacuum Hose Check Valve 3 N350 13 B96 3 3 2 Entrance 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 F 3 Vacuum Hose CCV No 3 3 N3A2 20 362 3 3 s Solenoid 3 3 ARAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAARAA 3 1 If part is removed replacement is necessary 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU COOLING FAN CO
610. ttery with a 600 rating indicates that the battery is 2 3 down on capacity This decline will occur through normal aging and does not necessarily indicate that the battery requires replacement It provides a general indication of the battery health for your customer IMPORTANT Diagnostic procedures for lead acid battery performance are different than those used for maintenance fr batteries lithium hybrid type Incorrect diagnosis will result in false readings and unnecessary battery replacement if the wrong procedure is followed Use the flow chart below Diagnostic procedures used for testing lead acid batteries provide false readings leading to unnecessary replacement if used on maintenance fr batteries The information below is provided for diagnosing maintenance fr batteries BATTERY DIAGNOSTIC PROCEDURES FLOW CHART 2 U AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Connect Test Leads To Battery And Switch To 3 2 Position A Pretest 1 3 UAAAAAAAAAAAAAAAAAY YES 3 Red Light ON AAAAAAAAA Bad Cell Replace Battery 3 NO AAAAAAAAAAAAAA
611. uel hoses and in rare cases engin compartment fires can result Therefore these vehicles must be repaired by replacing the fuel hoses with modified fuel hoses SUBJECT VEHICLES VEHICLE INFORMATION TABLE AAAAARARAAAAAARAAAAAARAAAARAAAAAAAAAAAAAAAAAAAAAA 3 Model Year amp Model 3 Vin Range RARAAARARAAARAAAAARARARARRARARAAAARAAARARARARAAAAR 3 L993 RX 7 3 JM1FD33 PO200001 210660 3 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 1994 95 RX 7 3 JM1FD33 RO300001 S0400026 3 Can be replaced by any letter or number 3 U OWNER NOTIFICATION The owners of the subject vehicles will be notified by first class mail around May 12 1995 REPAIR PARTS An initial quantity of Recall Labels are enclosed with this Service Bulletin Part Number 9999 94 5032E F Additional quantities can be ordered through normal parts ordering channels Following completion of the repair fill out the Recall Label with the appropriate information and affix it to left front driver s door RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright
612. ules used in Mazda vehicles do not use the day month or year to operate Mazda vehicles are completely immune to the effects of the year 2000 concern END OF ARTICLE A C O RING REPALCEMENT CAT U NO 95 10 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 03AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN A C O RING REPLACEMENT Model 5 All Mazda Models Canadian Category U Heater and Air Conditioning Systems Bulletin 95 10 Date October 1995 DESCRIPTION Refer to the figures on the following pages and the charts below when replacing air conditioning system O rings These O rings are designed for use in both R12 and R134 air conditioning systems Fig 1 indicates where a new O ring is measured to determine diameter and thickness Use this information and the chart above to identify the proper part if the O rings are accidentally mixed TM A D T 95E51940 Fig 1 Measuring New O Rings O RING APPLICATION TABLE en eee D ST 3 Pipe 3 O Ring E Part Numbers Quantity 3 3 Ring Size Size D X T 3 and 3 per 3 Code 3 3 3 Kit Numbers 3 Vehicle E de 3 A 3 8mm
613. umber for quality tracking purposes After retail delivery the tag must be kept with the vehicle service fil If a battery claim is made on the vehicle while in inventory or within 90 days after retail a copy of the Battery Check Tag must be attached to the repair order MAINTENANCE FREE BATTERY REVISED DIAG amp CHARGING CAT G NO 001 97 Article Text p 3 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 36PM SERVICING EQUIPMENT REQUIREMENTS In order to accurately and quickly check the condition of maintenance free batteries you should have available a digital volt meter capable of reading to 0 01 V and a battery tester utilizing load cells VAT 40 or equivalent or electronic testing Midtronics Power Sensor Plus VAT 40 testers require the battery to be charged to 12V or higher Midtronics tester requires 10 2V or higher to test and provides an indicator lamp confirming that the battery is OK to test See Special Tool Bulletin Cat ST No 003 95 for Midtronics purchase information CHARGING AND LOAD TESTING INFORMATION The table below gives specific charging amps times and load test amps for 1993 97 vehicles Refer to the applicable workshop manual for other model year vehicles and additional troubleshooting information INE ES a Can
614. under normal stem pressure he PCM may have been damaged during he fuel leakage test if the proper 3 rocedure was not followed To test he PCM 3 Connect a jumper wire from the pump terminal in the diagnostic i connector directly to a good j ground not in the connector 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Tu H s Engine does not get fuel Cranks but will not start TO ct H Crank the engine If the engine starts and remains running only as long as the connector is connected the PCM is 3 damaged and must be replaced 3 Engine cuts out on hard Check the secondary fuel injector 3 throttle but 3 connectors 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 accelerates normally If the connectors are not fully under light throttle 3 locked during reassembly they can 1 be mis positioned when the vacuum 3 3 pipe assembly is installed Connectors may appear to be in 2 place but not fully connected AAMAAAAAAAAAAAAAAAAAAAAAAAA
615. unleaded Fuel of 91 octane or higher END OF ARTICLE ENGINE STALLS DURING DECELLERATION REPLACE ECU CAT F NO 032 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 59AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ENGINE STALLS DURING WARM UP IDLE FLUCTUATION Model s 1993 Mazda RX 7 Category E Bulletin No 032 92 Date 12 23 92 AFFECTED VINS This bulletin applies to 1993 RX 7 M T models with a VIN of JMIFD3312P0208703 or lower produced through July 2 1992 This bulletin applies to 1993 RX 7 A T models with a VIN of JMIFD331XP0210513 or lower produced through September 30 1992 DESCRIPTION Some 1993 RX 7 vehicles may experience stalling during deceleration with the throttle release approaching a stop This occurs during initial warm up and sometimes after reaching normal operating temperatures The engine will then restart easily and stalling may not reoccur until the next cold engine start Also when idling with the A C on engine speed deceases as the A C compressor engages and idle fluctuation may occur The ECU has been modified as a countermeasure If any of the above symptoms are encountered replace the ECU The modified ECU is designed to 1 Make necessary air fuel ratio adjustments to maintain stable idle at a
616. urces Board CARB expects smog forming emissions from motor vehicles to decrease by approximately 15 due to CaRFG MAZDA S POSITION ON CaRFG CaRFG does not affect the new vehicle or emission warranty Mazda recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air Vehicle and laboratory testing of CaRFG ensures that CaRFG is acceptable for customer use Based on the above studies no unusual vehicle performance concerns are expected DIFFERENCE BETWEEN CaRFG AND OTHER GASOLINES CaRFG consists of the same basic components as other gasoline but pollutes less due to cleaner burning components and fewer toxic components These components provide Reduced aromatic hydrocarbons to form less smog emissions Added oxygenates to reduce emissions Decreases the amount of vehicle fuel evaporation Lower sulfur to provide more efficient catalytic converter 0X CALIFORNIA REFORMULATED GASOLINE CAT F NO 014 96 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 58AM operation Reduced benzene by approximately 50 CaRFG AFFECT ON VEHICLE PERFORMANCE Properly blended CaRFG should have no adverse affect on vehicle performance engine durability or fuel system components Basic components of CaRFG are not significantly
617. urs after replacing an intake manifold gasket may be caused by damage to the gasket If the proper torque sequence is not followed cracks and or breakage may occur INSTALLATION PROCEDURE Refer to the instructions and tightening sequences shown in Fig 1 when installing the gasket Make a note in the applicable workshop manuals to avoid problems during installation INTAKE MANIFOLD GASKET PRECAUTIONS CAT F NO 005 95 Article Text p 2 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 34AM W o CNN Step 1 Apply molybdenum grease to flange Do Not Apply To Gasket Step 2 Tightening Torque 16 20 Nm 1 6 2 3 kgfm 12 16ft Ibs 94G58863 Fig 1 Intake Manifold Gasket Tightening Sequences END OF ARTICLE INTAKE MANIFOLD GASKET PRECAUTIONS CANADIAN CAT F NO 95 03 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 35AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN INTAKE MANIFOLD GASKET PRECAUTIONS Model 5 1986 94 Mazda RX 7 Canadian Category F Fuel amp Emission Controls Bulletin No 95 03 Date ADF 1995 Date Revised June 1995 APPLICABLE MODEL VIN 1986 94 RX 7 Model Vehicles DESCRIPTION Rough idle that occurs after replacing an intake manifold gasket may be caused by da
618. use clips other than those included part number below Be sure to use two clips for the joint between the primary fuel distributor and the main fuel pipe see arrow in Fig 46 NOTE For the direction of the clips claw s step 27 2 Clip Primary N371 13 157 x 2 pcs Place the fuel distributor side clip claws on the top and the other one on the bottom N3Z1 13 157 x 2 94059339 Turn the clip claw sideways Dashboard side A B 8574 13 157 Fig 60 Connecting Hose Fuel Distributor amp Vacuum Pipe Assembly Place the Clip Claws in Opposite Directions RX 7 FUEL LEAKAGE RECALL CAMPAIGN 60504 CANADIAN Article Text p 42 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 06 56AM 32 3 Replace the main fuel hose with a new one S Fig 61 NOTE The hose and the clips shown in Fig 61 should be replaced with new ones Be careful not to use the hose and the clips other than those included part number s below Apply adhesive to the hose end short end side only indicated by the arrow in Fig 61 then install it To apply adhesive s step 27 1 Insertion depth of both hose ends should be 25 30 mm Fuel hose N32Z1 13 421 Clap 0574 13 157 x 2 pos 94F59340 Fig 61 Replacement of Main Fuel Hose 33 Check for fuel leakage WARNIN
619. ust 25 2001 09 58AM Terminals A and B 94E53029 Fig 2 Engine Signal Monitor ECU CHECK SHEET Dealer Name Technician Number Vehicle Year Model M T A T VIN Repair Date _ Mileage Repair Order Number 1 Customer Complaint 2 Was the customer s complaint verified Yes No 3 Reason for replacement Terminal Voltage Out Of Specification Yes No RARARARARAAAARARARARARARARARARAAAAAAAARARARARARARARAAAAAAAARA Terminal Number 7 Voltage Reading Factory Specification 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 3 3 U According to Service Bulletin instructions Category No According to DSM or Hot Line Authorization Authorization Other ECU AIR FLOW METER FUEL PUMP ALTERNATOR DIAGNOSTICS CAT G NO 002 93 Repair Type Technician s NOTE This c your s AIR FLOW METE Article Text p 5 1993 Mazda RX7 For www iluvmyrx7 com Copyrigh
620. ut voltage of speed 7 3 3 sensor 2 at EC AT control 3 3 unit OK 3 Acceptable Voltages 3 No 3 Go to next step 3 2 3 volts while driving 3 3 3 0 or 4 5 5 5 volts with 3 3 3 3 vehicle stopped 3 3 AAAAAAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 Remove combination meter 3 Yes Go to next step 3 3 3 Is there continuity 3 3 3 between 3E terminal of 3 3 3 meter connector and 1I 3 terminal of EC AT control No Repair or replace wiring 7 gt Unit j 3 and or connector B AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 4 3 Connect circuit tester to Yes Replace speedometer 3 E 3 3C and 3A terminals of 3 3 3 d 3 meter connector 3 3 3 3 Does pointer of circuit 3 tester move slightly when iNo Go to next step 3 3 rear wheels are slowly 3 3 3 turned j a A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 5 3 Remove speed sensor 2 3 Yes Go to next step 3 3 Is resistance felt when 5 3 3 turning speedometer driven A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 3 gear by hand 3 No Replace speed sensor 2 AAAAAAAAAAAAAAAAAAA
621. x Vehicles 3 3 No Coolant Leaks Coolant Leaks AR AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Warranty R R R 3 Type 3 3 3 3 AR AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Customer 99 99 3 99 3 3 Comment 3 3 3 3 3 Code 3 3 3 3 AKAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Damage 3 99 99 I 99 3 Code 3 3 3 3 AR AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA E Process A4014A 3 A4014B 3 A4014C 3 3 Number 3 3 A ARRARRARAAAAARAARAARAARAAAAARARAAARARAAARARAAAAAAAAAAAAAAAAAA 3 Part 5 N3Z1 15 S10B 3 N3Z1 15 S10B 5 N3Z21 15 S10B 3 3 Number 3 3 3 3 3 Main 3 3 3 3 3 Cause 3 3 3 3 3 PNMC 3 3 3 3 a a 5 3 Quantity 3 AARRARAAARAAAAARAARAARAARAAAAARAAAARARARAAAAAAAARAAARARAAAAAAAA 3 Related None 3 N3A1 13 S60 3 N3A1 13 S60 3 Part 3 3 N3Z21 15 820 3 3 Numbers 3 3 3 N3SGIoTt5sTT73 3 RECALL CAMPAIGN 54407 COOLANT LEAK 54407 Article Text p 29 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 37AM Quantity None 1 E for each P N AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAA 3 Labor 3 XX
622. y August 19 2001 01 47PM Vy Battery votiege Connected vo Teal condition Remark 1 2 swich 1s and 2nd position Ignuon awich ON MT 4 Other Reduce torque EC AT CU 2nd 3rd postion While running When shifting kom sl lo 2nd or from signa aT 2nd 16 3rd with the Inrottie opening above 1 5 8 Idle Sap tock up 1 2 swich ON l ignwon sien ON When slip lockup win the ihrolile apen sons MT 9 beton 0 5 6 Other OFF Nevirat igion smicn ON EC AT CU 3d or 0 0 position OFF While running in gear aT Diner ON Matesing igation swach ON to av Voltage mor Por N range e inhiblior sgnal O pump approx PV While accelerating eignition swich position ON sensor Accelerator pedal Cepressed 11 42V Heactignt swich position 1 t ON ignition swch OW und Blower motor postion M IV EN Rear dekosior switch ON Headight swich Biower molor rear de Woster Swach are OFF ON Approx OV Alter warm up Osculoscope piya ie 5 Acceleration Aller warm up Deceteration After warm up Engine speed hold 3 000 ipm aller 5 core fan Water Engine cootani lemperature 20 C i ignition swach ON thermosensor Engine coolant temperature EC Trrotte Accelerator pedal released 075 1 25 elgntion switch sensor Nar 48 50V ON row range Accelerator peda
623. y cable and No Intermittent poor connection 3 3 recheck for service cod 3 Check for cause 3 3 3 Is service code displayed 7 2 AAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAU EC AT CONTROL UNIT 94C55444 Fig 3 Service Code 06 Circuit Diagram gt U Service Code No 07 Speed Sensor 2 Speedometer Sensor AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Step Inspection Action ARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA WORKSHOP MANUAL CORRECTION EC AT DIAGNOSTIC CODES CAT W NO 034 92 Article Text p 6 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 07 25AM 3 1 3 Are there any poor 3 Yes Repair or replace connector 3 3 connections at speed 3 3 3 sensor 2 and EC AT control A A AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 unit connectors 3 No 3 Go to next step AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAARAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 2 3 Connect a circuit tester 3 Yes Go to Step 8 2 3 to terminals 11 and 3 3 3 3 3 ground as shown in Fig 4 3 3 3 3 3 Is inp
624. yer Removal Spread the SST toward the outside and pull the CD player straight The CD player should hang to the left of the radio Prop up the CD player so there is no unnecessary tension on the CD player wiring Push the SST into the holes on the sides of the radio until it locks See Fig 5 Fig 4 Ws out 8 NOTE 9 Erge S 10 Pull 11 The e 94454007 Radio Disconnection the stereo out about two inches lectrical connectors must now be removed from the back of the RADIO REMOVAL TIPS W CD PLAYER CAT T NO 018 92 Article Text p 4 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 42PM radio Since it is not possible to see the connectors refer to Fig 6 Remove the connectors in the order shown below and note the locations of the locking tabs A 8 Pin White connector locking tab is on top and should be pressed down B 12 Pin White connector locking tab is on the passenger s side right of the connector and should be pressed towards the driver s side left C 13 Pin DIN connector has no locking tab and should be pulled straight out D 1 Pin Ground connector locking tab is on top and should be pressed down NOTE The antenna leads going into the back of the radio are not removable a 8 Pin White b 12 Pin Whi
625. your dealer elects not to participate in the program disregard the box see note below NOTE If 1 your dealers old harness adapter is not received within 2 weeks of your receipt of the box or 2 your old harness adapter is non serviceable a new harness adapter will be shipped to you Your dealer s parts account will then be debited for 457 71 STEP 3 FOLLOWING THURSDAY Your dealer receives its updated harness adapter STEP 4 Your dealer s parts account is debited for 50 00 If there are any questions regarding this program be sure to contact Special Tools Manager at 714 442 6520 END OF ARTICLE ANTENNA MAST REPLACEMENT SERVICE CAT T NO 017 92 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Sunday August 19 2001 01 22PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN ANTENNA MAST REPLACEMENT SERVICE Model s Category Number Date DESCRIPTION 1992 Mazda 929 1993 Mazda MX 6 626 amp RX 7 017 92 9 22 92 Vehicles speci as replacement antenna assemb fied in Applicable Models have antenna masts available parts It is not necessary to replace th ntir ly motor and mast when only a mast is required At times the mast does not retract fully due to dirt build up around the mast area Periodic cleaning of the mast with a moist wash cloth is recommended END OF ARTICLE
626. zda B2300 B4000 Millenia Protege 1997 Mazda MPV Category Mazda Tips Bulletin No MT 0997 04 Date September 1997 DESCRIPTION Alan Carothers of Almaden Mazda in San Jose CA reported on a vehicle where an ABS sensor rotor was not seated properly on the axle shaft This caused the ABS light to come on intermittently and no problems were found using the ABS tester If you encounter this type of complaint first check the ABS sensor rotors for missing or damaged teeth then inspect the ABS sensor rotors for improper seating A rotor may have become loose and slipped out of alignment on the axle shaft You may be able to see marks on the axle from when the rotor was fully seated indicating it has moved If it appears that the rotor has slipped out of position replace the affected axle shaft and ABS sensor rotor END OF ARTICLE BRAKE CALIPER BOLT CORROSION CLEAN amp SEAL MT 0995 11 Article Text 1993 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday August 25 2001 09 24AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN BRAKE CALIPER BOLTS Model 5 All Mazda Models Category Mazda Tips Bulletin No MT 0995 11 Date 1995 DESCRIPTION When reinstalling disk brake calipers use the following procedure to secure the caliper bolts and seal against road corrosion When installing caliper mounting bolts first clean the bolt t

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