'94 Mazda RX-7 Factory Service Manual
Contents
1. Radiator TROUBLESHOOTING GUIDE Problem J Possibile cause Action Pase Overheating Coolant level insufficient Add E 5 Coolant leakage Repair Radiator fins clogged Clean Radiator cap malfunction Replace Coolant fan malfunction Replace Thermosiat malfunction Replace Water passage clogged Clean Water pump malfunction Replace Impurities in coolant _ 3 ENGINE COOLANT ENGINE COOLANT PREPARATION SST 49 9200 145 49 9200 146 ime 1 For inspection of inspection of Adapter set cooling system Adapter A cooling system radiator cap pressure tester 49 9200 146 4 Part of pressure 49 9200 145 INSPECTION Coolant Level Engine cold 1 Verify that the coolant level is near the filler neck 2 Verify that the coolant level on the dipstick i is between the F and L 3 Add coolant if necessary Note The distance between the L and F marks on the dipstick represents 1 0 Liter 1 1 US qt 0 9 Imp qt Coolant Quality Warning e Removing the radiator cap or the coolant filler cap while the enginei is running or when the engine and radiator are hot is dangerous Scalding coolant and steam may shoot out and cause serious injury it may also damage the engine and cooling system Turn off the engine and wait until it is cool Even then be very careful when removing the cap Wra2. Drain the engine coolant Refer to page E 5 3 Remove in the order shown in the figure 4 install in the reverse order of removal referring to Installation Note 19 25 2 1 92 6 14 18 7 8 10 7 Nem 80 110 kgf cm 70 95 4 In Ibf 7 9 10 7 N m 180 110 kgf cm 70 95 4 in Ibf N m kgf m ft Ibf 6 Radiator hose upper 1 Fresh air duct 7 Coolant level sensor connector 2 Air cleaner housing 3 Water hose 8 Thermostat cover 4 Air pump 9 Thermostat and gasket 5 Drive belt Inspection page E 15 Removal installation Section C Installation Note page E 15 E 14 THERMOSTAT WATER PUMP AND WATER THERMOSENSOR E INSPECTION 1 Visually check that the thermostat valve is airtight 2 Place the thermostat and a thermometer in water 3 Heat the water and check the following Initial opening temperature 80 5 83 5 C 177 182 F Full open temperature 95 C 203 F Full open lift 8 0 10 mm 0 31 0 39 min 4 Check the thermostat gasket if damaged replace the thermostat assembly Installation Note Thermostat Install the thermostat into the thermostat case with the jiggle pin at the top Steps After Installation 1 Fill the radiator with the specified amount and type of engine coolant Refer to page E 5 6 2 Connect the negative battery cable 3 Start the engine and check for leaks 4 Bleed the cooling system Refer to p
3. his file is available for free download at htto www iluvmyrx com This file was not scanned to deprive Mazda of any money it was scanned due to the rareness of the original manuals and the overwhelming need of the RX 7 owner to have this information so that they can accurately troubleshoot problems Perhaps if Mazda 5 dealerships could support the Rotary Engine it wouldn t be so necessary for the owners to do so Many thanks to Lenny Terris for scanning this Ne alarm conditions COOLING SYSTEM 2 OUTLINE c sco d aes E 3 SPECIFICATIONS S E 8 TROUBLESHOOTING GUIDE E 3 ENGINE COOLANT E 4 PREPARATION E 4 INSPECTION E 4 REPLACEMENT E 5 RADIATOR CAP occu Boy PREPARATION E 7 INSPECTION 36 cubi es exp E 7 RADIATOR AND COOLANT FAN E 8 REMOVAL INSTALLATION E 8 INSPECTION E 10 REPLACEMENT 12 COOLANT FAN RELAY E 13 REMOVAL INSTALLATION E 13 INSPECTION eee nnne E 13 THERMOSTAT E 14 REMOVAL INSTALLATION E 14 INSPECTION 2 E 15 WATER PUMP AND WATER THERMOSENSOR E 15 REMOVAL INSTALL
4. ATION DK E 15 INSPECTION E 17 Before beginning any service procedure refer to the 1994 RX 7 Body Electrical Troubleshooting Manual see section S for air bag system service warnings and section J1 for audio antitheft system INDEX INDEX FILLER CAP COOLANT CAPACITY 8 8L 9 305 qt 7 71 qt 1 Radiator cap Inspection page E 7 2 Radiator Removal Installation page E 8 INSDOCUON page E 10 3 Coolant fan motor Inspection page E 11 Replacement page E 12 E 2 4 Coolant fan relay Removal Installation page E 13 Inspection page E 13 5 Thermostat Removal Installation page E 14 Inspection page 15 6 Water pump and water thermoswitch Removal Installation page E 15 Inspection page E 17 OUTLINE TROUBLESHOOTING GUIDE E OUTLINE SPECIFICATIONS Engine model 13B Turbo Cooling system Coolant capacity L US at Imp at Thermostat Fulcopen temperature TEF Full open lift fin Cap valve opening pressure kPa kgf cm psi _ 113 142 1 15 1 45 16 4 20 6 Motor current A High 10 6 16 6 Med 6 5 12 5 Low 5 8 11 8 Coolant fan Number of blades 1 5 2 4 Outer diameter of blades No 1 No 2 300 11 8
5. age E 6 WATER PUMP AND WATER THERMOSENSOR REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Drain the engine coolant Refer to page E 5 3 Remove in the order shown in the figure page E 16 referring to Removal Note 4 Install in the reverse order of removal E 15 WATER PUMP AND WATER THERMOSENSOR 3 8 8 3 28 38 7 9 10 7 N m 7 9 10 7 N m 80 110 kgf cm 70 95 4 in Ibf 10 33 1 01 4 8 10 S GASKET an REPLACE ACK 1 Fresh air duct 2 Battery and carrier 3 Air funnel and air hose 4 Accelerator cable Service Section F 5 Air cleaner housing 6 Water hose filler port 7 Air pipe and air hose 8 Water pump pulley 9 Drive belt Removal Installation Section C 10 Water hose water pump body E 16 7 9 10 7 N m 180 110 kgf om 1 70 95 4 in ibi 19 25 1 9 2 6 14 18 2 GASKET 73 107 Nem 80 110 kgf cm 70 95 4 in Ibfj 7 9 10 7 N m 80 110 kgf cm 70 95 4 in lbf 80 110 kgf cm 70 95 4 7 9 10 7 N m 180 110 kgf cm d gt W 180 110 kgf cm A 70 95 4 in ibf 1 9 2 6 14 18 i i p 19 25 kgf m ft Ibf 11 Alternator and strap 12 Air pump and strap 13 Radiator hose upper 14 Charge air cooler and air separation tank Removal Note page E 17 15 Sub
6. eed inspection 6 Verify that the fan motor operates smoothly at the stan dard current or less with the switch ON Current 6 5 12 5A 7 Connect battery positive voltage an ammeter and a switch to the fan motor connector as shown for high speed inspection 8 Verify that the fan motor operates smoothly at the stan dard current or less with the switch ON Current 10 6 16 6A 9 Check the other fan motor as described above 10 If a fan motor does not operate as specified replace it E 11 RADIATOR AND COOLANT REPLACEMENT 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 24 32 1 8 2 1 N m 18 22 kgf cm 16 19 in Ibf 1 Radiator cowling 3 Coolant fan motor 2 Coolant fan E 12 cmt COOLANT FAN RELAY E COOLANT FAN RELAY REMOVAL INSTALLATION Slide the coolant fan relays off the bracket The relay positions are shown in the figure Body side INSPECTION 1 Check continuity of the relaly as shown pec uu c ae 2 Apply 12V between terminals c and d Check for continuity between terminals a and b 3 If not as specified replace the fan relay Steps After Installation 1 Fill the rediator with the specified amount and type of engine coolant Refer to page 5 2 Start the engine and check for leaks E 13 THERMOSTAT THERMOSTAT REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2
7. frame 16 Radiator hose lower 17 Heater hose 18 Water hose water pump body 19 Metering oil tube 20 Water pump and pump body Removal Note page E 17 21 Water thermosensor Inspection page E 17 Installation Note page E 17 WATER PUMP AND WATER THERMOSENSOR E Removal Note Charge air cooler and air separation tank Do not remove the air duct from the body Water pump and pump body 1 Remove the metering oil pump connector from the engine hanger 2 Remove the bolt amp shown in the figure 3 Position the metering oil tube and metering oil pump har ness under the lower radiator hose 4 Remove the nuts shown in the figure 5 Remove the water pump and pump body 27 A 2744 7 M ay wi INSPECTION Water Thermosensor 1 Place the switch and a thermometer in water 2 Heat the water gradually and check resistance of the Switch 101 C 214 F 108 C 236 3 If not as specified replace the water thermosensor Installation Note Water thermosensor 1 Apply a small amount of engine coolant to the new O ring 2 Install the water thermosensor Tightening torque 5 9 8 8 Nm 60 90 kgf cm 52 78 in ibf E 17
8. gn material such as water residue from be tween the radiator cap valve and the valve seat 2 Attach the radiator cap to a radiator cap tester commer cially available by using the SST Apply pressure gradu ally to 113 142 kPa 1 15 1 45 kgf cm 16 4 20 6 psi 3 Wait about 10 seconds Verify that the pressure has not decreased 4 If not as specified replace the radiator cap Negative Pressure Valve 1 Pull the negative pressure valve to open it Verify that it closes completely when released 2 Check for damage on the contact surfaces and for cracked or deformed seal packing 3 Replace the radiator cap if a problem is found RADIATOR AND COOLANT FAN RADIATOR AND COOLANT FAN REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Drain the engine coolant Refer to page E 5 3 Remove in the order shown in the figure referring to Removal Note 4 Install in the reverse order of removal STEP 1 7 9 10 7 Nem 80 110 kgf cm 70 95 4 in fbf 7 9 10 7 N m 80 110 kgf cm 70 95 4 in Ibf kgf m ft Ibf 5 Relay box 1 Fresh air duct 6 Coolant fan motor connector 2 Air cleaner housing 3 Battery and carrier 4 Radiator hose upper E 8 RADIATOR AND COOLANT FAN E STEP 2 37 53 22 3 7 5 5 27 39 18 26 1 8 27 14 19 1 Undercover 2 Stabilizer and bracket Removal Inspection 3 Radiator hose lower 4 Air separa
9. p a thick cioth around it and slowly turn it counter clockwise to the first stop Step back while the pressure escapes When you re sure all the pressure is gone press down on the cap still using a cloth turn it and re move it 1 Verify that there is no buildup of rust or scale around the radiator cap or filler neck 2 Verify that coolant is free of oil Replace the coolant if nec essary Coolant Leakage 1 Connect a radiator tester commercially available and the SST to the radiator filler neck Caution Applying more than 142 kPa 1 45 kg cm 20 6 psi can damage the hoses fittings and other compo nents and cause leaks 2 Apply 142 kPa 1 45 kgf cm 20 6 psi of pressure to the system 3 Verify that the pressure is held 4 If not as specifed check for coolant leakage ENGINE COOLANT E Coolant Protection Caution COOLANT PROTECTION SPECIFIC The engine has aluminum parts that be dam aged by alcohol or methanol antifreeze Do not use alcohol or methanol in the cooling system Use only ethylene glycol based coolant Caution Use only soft demineralized water in the coolant mixture Water that contains minerals will cut down on the coolant s effectiveness 1 Measure the coolant temperature and the specific gravity with a thermometer and a hydrometer 2 Determine the coolant protection by referring to the graph shown 3 If the coolant protection is not proper add wa
10. qt min max Coolant capacity 8 8 L 9 3 US qt 7 7 Imp gt min max 2 Fill the coolant reservoir up to the F mark 3 Securely install the radiator cap and the coolant filler cap 4 Start the engine and let it idle about 10 minutes until it warms up 5 lf the coolant level warning light comes on while warming up turn the engine off and inspect the drain plug and wa ter hoses for leaks 6 Stop the engine and allow it to cool Warning Removing the radiator cap or the coolant filler cap while the engine is running or when the engine and radiator are hot is dangerous Scalding coolant and steam may shoot out and cause serious injury It may also damage the engine and cooling system Turn off the engine and wait until it is cool Even then be very careful when removing the cap Wrap a thick cloth around it and slowly turn it counter clockwise to the first stop Step back while the pressure escapes When you re sure all the pressure is gone press down on the cap still using a cloth turn it and re move it 7 Check the coolant level If it s low repeat the procedure from step 1 8 Fill the reservoir to the F mark m RADIATOR CAP E RADIATOR CAP PREPARATION SST For inspection of Adapter set radiator cap Adapter B radiator cap radiator cap valve valve tester 49 9200 145 49 9200 145 For 49 9200 147 inspection of INSPECTION Radiator Valve 1 Remove forei
11. ter or cool 04 32 50 E 66 104 122 140 158 17611194 Antifreeze solution mixture percentage COOLANT TEMPERATURE C F Volume percentage ant Gravity at o o Coolant protection Coolant 20 C 68 F Above 16 3 F nove s 4 6 Above 40 C 40 F REPLACEMENT Draining Warning Removing the radiator cap or the coolant filler cap while the engine is running or when the engine and radiator are hot is dangerous Scalding coolant and steam may shoot out and cause serious injury It may also damage the engine and cooling system Turn off the engine and wait until it is cool Even then be very careful when removing the cap Wrap a thick cloth around it and slowly turn it counter clockwise to the first stop Step back while the pressure escapes When you re sure all the pressure is gone press down on the cap still using a cloth turn it and re move it 1 Remove the radiator cap 2 Loosen the radiator drain plug 3 Drain the coolant into a container 4 Flush the cooling system with water until all traces of color are gone 5 Let the system drain completely 6 Install and tighten the drain plug E 5 ENGINE COOLANT Refilling Use the proper amount and mixture of ethylene glycol based coolant Refer to Coolant Protection page E 5 1 Slowly pour the coolant into the radiator up to the coolant filer neck Filling pace 1 0 L 1 1 US qt 0 9 Imp
12. tion hose 7 9 10 7 N m NE 70 95 4 in Ibf b PA 5 N m kgf m ft Ibf 5 Oil cooler hose AT 6 Radiator and coolant fan Section R Removal Note Removal Note Radiator and coolant fan While removing the radiator and cooling fan do not dis connect the A C piping 1 Remove the bolts shown in the figure 2 Position the A C condenser away from the radiator and secure it with wire E 9 RADIATOR AND COOLANT FAN 3 Remove the P S oil pump pipe bracket shown in the fig ure 4 Remove the A C compressor high pressure pipe bracket as shown in the figure 6 Remove the radiator and coolant fan INSPECTION Radiator Check for the following and repair or replace the radiator as necessary 1 Cracks damage and water leakage 2 Bent fins repair with a screwdriver 3 Damaged radiator inlet outlet and hose connectors 5 Remove the radiator bracket E 10 RADIATOR AND COOLANT E Coolant fan motor 1 Verify that the battery is fully charged 2 Disconnect the fan motor connectors 3 Connect battery positivo voltage and an ammeter as shown to the fan motor connector for low speed inspec tion 4 Verify that the fan motor operates smoothly at the stan dard current Current 5 8 11 8A 5 Connect battery positive voltage an ammeter and a switch to the fan motor connector as shown for medium sp
Download Pdf Manuals
Related Search