'94 Mazda RX-7 Factory Service Manual
Contents
1. Gi 14 VOLTMETER Gl 14 14 ELECTRICAL PARTS GI 15 BATTERY CABLE 01 15 CONNECTORS GI 15 TERMINALS Gl 16 SENSORS SWITCHES AND RELAYS GI 17 WIRING HARNESS Gi 17 uic APP cetacean tan Gl 17 INSTALLATION OF MOBILE TWO WAY RADIO Gl 18 AUDIO ANTITHEFT SYSTEM Gl 18 TOWING REX Rn ied GI 19 GI SAFETY INFORMATION SAFETY INFORMATION LUBRICANTS Avoid prolonged and repeated contact with petroleum based oils Used oil may irritate the skin and can cause skin cancer and other skin disorders Wash thoroughly after working with oil We recommend water soluble hand cleaners Do not use kero sene gasoline or any other solvent to remove oil from your skin If repeated or prolonged contact with oil is necessary wear protective clothing Soiled clothing particular ly those soiled with used oils and greases containing lead should be cleaned at regular intervals JACKING POSITIONS Warning Improperly jacking a vehicle is dangerous The vehicle can slip off the jack and cause serious injury Use only the correct front and rear jacking positions and block the wheels Use safety stands to support the vehicle after it has been lifted2. MANUAL STEERING PREPARATION SST NUMBER 49 0118 850 For removal of tie rod end 49 0118 850C For removal of tie rod Puller joint end Puter bali joint SST NAME SST ILLUSTRATION REPAIR PROCEDURE 1 Most repair operations begin with an overview illustration It identifies the components shows how the parts fit together and describes visual part inspection If a damaged or worn part is found repair or re place it as necessary 2 Expendable parts tightening torques and symbols for oil grease and sealant are shown in the overview illustration 3 Pages related to service procedures are shown Under the illustration Refer to this information when servicing the related part GI 4 HOW TO USE THIS MANUAL Gl Example 72 107 7 4 18 9 ett SHOWS TIGHTENING PENDABLE TORQUE 3 SPECIFICATIONS 2 SHOWS APPLICATION POINT OF OIL ETC SHOWS TIGHTENING TORQUE UNITS SHOWS VISUAL SHOWS INSPE RELATED INFORMATION PAGE FOR SERVICE 1 The numbers etc refer to part identification and servicing procedures 2 Units are in N m kgf m ft ibf unless otherwise specified SYMBOLS There are six symbols indicating oil grease and sealant These symbols show the points of applying such materials service Apply brake fluid New engine oil or gear oil as appropriate FMVSS116 DOT 3 Apply automati
3. Replacement Use the appropriate tools to remove a terminal as shown When installing a terminal be sure to insert it until it locks securely Insert a thin piece of metal from the terminal side of the connector and then with the terminal locking tab pressed down pull the terminal out from the connector GI 16 ELECTRICAL PARTS GI SENSORS SWITCHES AND RELAYS Handle sensors switches and relays carefully Do not drop them or strike them against other objects WIRING HARNESS Wiring color codes Two color wires are indicated by a two color code symbol BROWN The first letter indicates the base color of the wire and the second the color of the stripe YELLOW CODE BR EE FUSE Replacement 1 When replacing a fuse be sure to replace it with one ofthe specified capacity If a fuse again fails after it has been replaced the circuit probably has a short and the wiring should be checked 2 Be sure the negative battery terminal is disconnected be fore replacing a main fuse 80 3 When replacing a pullout fuse use the fuse puller sup plied in the fuse box cover Gl 17 3l INSTALLATION OF MOBILE TWO WAY RADIO SYSTEM AUDIO ANTITHEFT SYSTEM INSTALLATION OF MOBILE TWO WAY RADIO SYSTEM If a mobile two way radio system is installed improperly or if a high powered type is used the CIS and other systems may be affected When the vehicle is to be equipped with a mobile two
4. Front Rear At the center of the crossmember At the center of the crossmember SAFETY STAND POSITIONS Front Rear Both sides of the vehicle Both sides of the vehicie GI 2 SAFETY INFORMATION Gl VEHICLE LIFT POSITIONS Front Rear DYNAMOMETER When test running a vehicle on a dynamometer Place a fan preferably a vehicle speed proportional type in front of the vehicle Connect an exhaust gas ventilation unit Cool the exhaust pipes with a fan Keep the area around the vehicle uncluttered Waich the water temperature gauge COMPRESSED AIR When using compressed air to clean or remove parts Wear protective eyewear Hold a rag over the opening to prevent parts from shooting out Take precautions so that people around you are not struck by flying debris GI 3 Gl HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL ADVISORY MESSAGES You ll find several Warnings Cautions and Notes in this manual Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored Caution A Caution indicates a situation in which damage to the vehicle could result if the caution is ig nored Note A Note provides added information that will help you to complete a particular procedure PREPARATION This points out the needed SSTs for the service operation It is best to gather all necessary SSTs before beginning work Example
5. his file is available for free download at htto www iluvmyrx com This file was not scanned to deprive Mazda of any money was scanned due to the rareness of the original manuals and the overwhelming need of the RX 7 owner to have this information so that they can accurately troubleshoot problems Perhaps if Mazda s dealerships could support the Rotary Engine it wouldn t be so necessary for the owners to do so Many thanks to Lenny Terris for scanning this 1994 Mazda RX 7 Workshop Manual WARNING Servicing a vehicle can be dangerous If you have not received service related training the risks of injury and property damage increase The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda trained technicians in mind This manual may be useful to non Mazda trained technicians but a techni cian with our service related training and experience will be at less risk when performing servicing operations However ail users of this manu al are expected to know general safety procedures This manual contains Warnings and Cautions applicable to risks not normally encountered in a general technician s experience They should be followed to reduce the risk of injury and the riskthat improper service or repair may damage the vehicle or render it unsafe It is also important to understand that the Warnings and Cautions are not ex haustive It is impossible to warn of
6. all the hazardous consequences that might result from failure to follow the procedures The procedures recommended and described in this manual are effec tive methods of performing service and repair Some require tools specifically designed for a specific purpose Nonrecommended proce dures and tools should include consideration for safety of the techni cian and continued safe operation of the vehicle Parts should be replaced with genuine Mazda replacement parts not parts of lesser quality Use of a nonrecommended replacement part should include consideration for safety of the technician and continued safe operation of the vehicle 1993 Mazda Motor Corporation Printed in the U S A 8 93 Form No 1378 10 93H Part No 9999 95 018B 94 1994 Mazda RX 7 Workshop Manual FOREWORD A thorough familiarization with this manual is important for proper repair and mainte nance should always be kept in a handy place quick and easy reference The contents of this manual including drawings and specifications are the latest available at the time of printing As modifica tions affecting repair or maintenance occur relevant information supplementary to this volume will be made available at Mazda dealers This manual should be kept up to date Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or advance notice All rights reserved No part of t
7. c transmission fluid Dexron 1I or Appropriate grease Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly GI 5 Gl IDENTIFICATION NUMBER LOCATIONS UNITS IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER VIN AUTOMATIC TRANSMISSION MODEL AND NUMBER UNITS Electrical current n Electric potential Electric power auo MOREM mm millimeters in inches Negative pressure kPa kilo Pascal mmHg millimeters of mercury inHg inches of mercury Positive pressure kPa kilo Pascal kgf cm kilogram force per square centimeter psi pounds per square inch Resistance Q ohm Torque N m Newton meter m kilogram force per meter cm kilogram force per centimeter ft Ib foot pounds in Ib inch pounds Volume L liter US qt U S quart Imp qt Imperial quart Gl 6 ABBREVIATIONS G ABBREVIATIONS TERETNE Auto adjusting suspension ABDC After bottom dead center ABS Anti lock braking system ACO Accessories ACV ER Air control valve Air supply valve sees wep ey eH Automatic transmission After top dead center EE RET Aut
8. ease the parking brake With manual transmission If the transmission rear axle and steering system are not damaged the vehicle may be towed on all four wheels If any of these components are damaged use wheel dol lies With automatic transmission If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground use wheel dollies If all four wheels are on the ground the vehicle may be towed only forward Don t exceed 45 km h 28 mph and a distance of 15 km 10 miles you could damage the trans mission If speed must exceed 45 km h 28 mph or a towing dis tance of 15 km 10 miles use one of these methods Place the rear wheels on a dolly Tow with the rear wheels off the ground e Disconnect the propeller shaft If the transmission or rear axle is inoperative tow with the rear wheels off the ground Caution Don t tow with sling type equipment This could damage yourvehicle Use wheel lift or flatbed equip ment Caution Don t use the hook loops under the front for tow ing They are designed ONLY for tying down the ve hicle when it s being transported Using them for towing will damage the bumper etna a i STI AREA E TV EET RETINA ESN SHI NS GI 19
9. he appropriate method Warning Using compressed air can cause dirt and other par ticles to fly out causing injury to the eyes Wear protective eye wear whenever using compressed air REASSEMBLY Standard values such as torques and certain adjust ments must be strictly observed in the reassembly of all parts Refer to STANDARD BOLT AND NUT TIGHT ENING TORQUE in section TD for tightening torques not mentioned in the main text If removed these parts should be replaced with new ones 1 Oil seals 4 Gaskeis 2 O rings 5 Lock washers 3 Cotter pins 6 Nylon nuts Depending on location 1 Sealant should be applied to gaskets 2 Oil should be applied to the moving components of parts 3 Specified oil or grease should be applied atthe prescribed locations such as oil seals before reassembly GI 12 FUNDAMENTAL PROCEDURES Gl ADJUSTMENTS Use suitable gauges and testers when making adjust ments RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tub ing HOSE CLAMPS When reinstalling position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit TORQUE FORMULAS When using a torque wrench SST combination the writ ten torque must be recalculated due to the extra length that the SST adds to the torque wrench Recaiculate the torque by using the following formulas Choose the formu la that applies
10. her related names are unchanged GI 10 FUNDAMENTAL PROCEDURES Gi FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders seats and floor areas before starting work PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equip ment are available before starting any work SPECIAL TOOLS Use special tools when they are required REMOVAL OF PARTS While correcting a problem try also to determine its cause Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair After removing the part plug holes and ports to prevent foreign material from entering DISASSEMBLY If the disassembly procedure is complex requiring many parts to be disassembled all parts should be disas sembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently Gl 11 GI FUNDAMENTAL PROCEDURES 1 Inspection of parts When removed each part should be carefully inspected for malfunctioning deformation damage and other prob lems 2 Arrangement of parts All disassembled parts should be carefuily arranged for reassembly Be sure to separate or otherwise identify the parts to be replaced from those that will be reused 3 Cleaning parts for reuse All parts to be reused should be carefully and thoroughly cleaned in t
11. his book may be reproduced or used in any form or by any means electronic or mechanical in cluding photocopying and recording and the use of any kind of information storage and re trieval system without permission in writ ing WARRANTY The manufacturer s warranty on Mazda vehicles and engines can be voided if im proper service or repairs are performed by persons other than those ai an Authorized Mazda Dealer Mazda Motor Corporation HIROSHIMA JAPAN APPLICATION This manual is applicable to vehicles begin ning with the Vehicle Identification Numbers VIN shown on the following page CONTENTS Title General Information Pre Delivery Inspection and Scheduled Maintenance Lubrication System Cooling System Fuei and Emission Control Systems Engine Electrical System oM NENNEN ME Clutch Manual Transmission Electronically Controlled Automatic Transmission Propeller Shaft Front and Rear Axles Steering System Braking System b Wheels and Tires Suspension Body Electrical System 2 Heater and Air Conditioner Systems Technical Data ST Special Tools Wiring Diagram Form No 5273 10 83H Part No 9999 95 0220 94 Refer to the 1994 RX 7 Body Electrical Trou bleshooting Manual Form No 1380 10 93H Part No 9999 95 085F 94 for servicing of the body electrical components 1993 Mazda Motor Corporation Pri
12. ine and Emission Systems cont d SAE Standard Previous Standard Abbrevietion Name Abbreviation Remark eme Change Ar Cooler C KS Knock Sensor Malfunction Indicator Light Maifunction Indicator Light Multiport Fuel Injection Multiport Fuel Injection idation Catalyst Heated Oxygen Sensor ies Q Oxidizing Converter HO2S With heater Oxygen Sensor dn Oxygen Sensor KS IL F C Open Loop OL pen Loop FE AP VS CU C Positive Temperature Coefficient Heater EFE Early Fuel Evaporation E Manifold Absolute Pressure Sensor M Pressure Sensor f Checks Manifold Vacuum Sensor vacuum only Reed Valve SAPV Secondary Air Pulse Valve Relief 1 Solenoid Valve SABV Secondary Air Bypass Valve Pulsed Secondary Air injection Secondary Air Injection System EN i Pulsed injection EN Sequera Fusion Sequentia Multipoint Fuel T service Code s Diagnostic Trouble Code s sparkigniton D BDsbwognion Supercharger E Switching Solenoid Valve pom DTM T TPS Diagnostic Test Mode s Three Way Catalyst Throttle Body Throttle Position Sensor Turbocharger Manifold Differential Pressure Manifold Vacuum Zone Switch Engine Coolant Temperature Sensor Test Mode s Three Way Catalyst Throttle Body Throttle Sensor Turb
13. nted in the U S A 8 93 Form No 1378 10 93H Part No 9999 95 018B 94 VEHICLE IDENTIFICATION NUMBERS VIN JMiFD 333 300001 GENERAL INFORMATION SAFETY INFORMATION Gi 2 LUBRICANTS bein Gl 2 JACKING POSITIONS Gl 2 SAFETY STAND POSITIONS GI 2 VEHICLE LIFT POSITIONS GI 3 DYNAMOMETER Gi 3 COMPRESSED AIR Gl 3 HOW TO USE THIS MANUAL Gl 4 ADVISORY MESSAGES Gl 4 PREPARATION Gl 4 REPAIR PROCEDURE Gi 4 SYMBOLS Gl 5 IDENTIFICATION NUMBER LOCATIONS Gl 6 UNITS Gi 6 ABBREVIATIONS Gl 7 SAE STANDARDS Gi 8 FUNDAMENTAL PROCEDURES GI 11 PROTECTION OF THE VEHICLE GI 11 PREPARATION OF TOOLS AND MEASURING EQUIPMENT ci ccs eese eae Oda cues GI 11 SPECIAL TOOLS Gl 11 REMOVAL OF PARTS GI 11 DISASSEMBLY 01 11 GI 12 ADJUSTMENTS Gl 13 RUBBER PARTS AND TUBING Gl 13 HOSE CLAMPS 1 13 TORQUE FORMULAS Gl 13 VISE os sedere hn o ren Gl 13 ELECTRICAL TROUBLESHOOTING TOOLS AMEND Gl 14 TEST UONI GI 14 JUMPER WIRE
14. ocharger Vacuum Switch MVZS ECTS Water Thermosensor 6 Supplies air to three way catalytic 7 Diagnostic trouble codes depend on the test mode GI 9 Gl SAE STANDARDS Transmission Transaxle and Steering System Previous Standard SAE Standard Abbreviation Name Abbreviation Name Remak _ E a Giutch Pedal Position P EC AT Control Unit PCMT Transmission Postion FulyOpn WOT Wide Open Throttle ERES Inhibitor Switch PNS PaxNewalSwih _ P bock UpPosiion Torque Converter Clutch ouwwSgeis IOS Powertrain Control Signals 4 Fea Power Steering Pressure Switch SPS__ Steering Pressure Sensor __ f Puse Generator VSPG Vehicle Speed Pulse Generator J VedeSpeedSemo vss VedeSpeedSemot 0 Body Electrical System and Heater and Air Conditioner Systems SAE standard Previous Standard Abbreviation Abbreviation Air Conditioning Sensor A C Switch ACS Air Conditioner B OBD Air Conditioner Battery Voltage Coolant Level Sensor COLS Coolant Level Sensor Be Battery Positive Voltage Les OBD On Board Diagnosis System Self Diagnosis System 8 System name Ot
15. omatic transmission fluid ATS Ambient temperature sensor AWS ere Accelerated warm up system BAG ve ns coul Bypass air control BBDC Before bottom dead center BTDG vies Before top dead center Electronically controlled Automatic Transmission ECPS Electronically controlled power steering EDU Engine control unit Electronic gasoline injection ess Electrical load sen aneis Electronic spark advance 5 5 ere Engine speed sensing power steering EES sav dice erie vs Evaporator temperature sensor EX Exhaust Integrated circuit Ignition IN Koad weaken Intake a Intermittent ONE speed control ves Left hand LSD Limited slip differential M Motor MOP Metering pump whee Manual transmission DD ad perdes e Overdrive OFF Switch off ON ini et tees eae Switch on PBV Loos eee as Proportioning bypass valve PCTS Passenger compartment temperature sensor PCV Positive crankcase ventilation PRC Pressure regulator control P S Power steering PAN Power window Right hand RTS Reduce torque signal SLS cantar tectus Slip lockup signal SR Du EUR Sensor rot
16. or SOLE edt oid we vs Special service tool SI aav qudd ades Stat SW Switch ies EE Top dead center TNS Tail number side TRS Torque reduced signal VBI Variable dynamic effect intake VRIS Variable resonance induction system WSS oor veu Wheel speed sensor Water temperature sensor GI 7 Gl SAE STANDARDS SAE STANDARDS In accordance with new regulations SAE Society of Automotive Engineers standard names and abbrevi ations are now used in this manual The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents Engine and Emission Systems Previous Standard Abbreviation Name Abbreviation SAE Standard Remark Oxidation Catalyst Three Way Catalyst Warm Up Three Way Catalyst Fuel Pump Relay Coolant Fan Control Crankshaft Position Sensor ata Link Connector Distributorless Ignition Continuous Fuel injection System Electronic ignition EGR Function Control Abbreviation Abbreviation Name Remark Accelerator Pedal AP AcosleratorPedal AirCleaner ACH Air Cleaner Housing o o o o ooo A F Solenoid Vave Mixture Control Solenoid F2Carburetor Airflow Meter VAF Volume Airtiow Sensor fo ooo Sensor MAF Mass Aiflow Sensor po Aternator Alternator A
17. tance be tween two points in a circuit and to check for continuity and short circuits Caution Do not connect the ohmmeter to any circuit to which voltage is applied this will damage the ohm meter 91 14 _ ELECTRICAL PARTS Gl ELECTRICAL PARTS BATTERY CABLE Before disconnecting connectors or removing electrical parts disconnect the negative battery cable CONNECTORS Data Link Connector Insert the probe into the service hole when connecting a jumper wire to the data link connector Caution inserting a jumper wire probe into the data link con nector terminal may damage the terminal Disconnecting Connectors When disconnecting two connectors grasp the connec tors not the wires Connectors can be disconnected by pressing or pulling the lock lever as shown Locking Connectors When locking connectors listen for a click that will indi cate they are securely locked Gl 15 Gl ELECTRICAL PARTS Inspection 1 When a tester is used to check for continuity or to mea sure voltage insert the tester probe from the wiring har ness side 2 Check the terminals of waterproof connectors from the connector side as they cannot be accessed from the wir ing harness side Caution To prevent damage to the terminal wrap a thin wire around the lead before inserting it into the terminal TERMINALS Inspection Pull lightly on individual wires to check that they are se cured in the terminal
18. tmospheric Pressure Sensor BARO Barometric Absolute Pressure Sensor F carburetor Carburetor TC Oxidation Catalyst Three Way Catayst Catalytic Converter C 5 S Cooling Fan Control Crank Angle Sensor Diagnosis Connector Direct ignition Electronic Gasoline Injection System Circuit Opening Relay ca FPR CFC CPS DLC EGRS EGR Function Sensor 4 CIS CM Powertrain Control Module Powertrain Control Module Engine P ECU Engine Control Unit PCME Engine Modification Engine Modification PowemanCowdMohie Powertrain Control Module EM Engine Engine Speed Evaporative Emission Control System EVA Fuel Evaporative System Exhaust Gas Recirculation System EGR Exhaust Gas Recirculation Systemname_ PTT Feedback System Closed Loop System a _ RmePmp F Remp Voltage Regulator 5 0 O 311 Directly connected to exhaust manifoid 2 In some models there is a Fuel Pump Relay that controls pump speed That relay is now called the Fuel Pump Relay Speed 3 Controlled by the PCME PCM 4 EGR valve controller device name 5 Device that controls engine and powertrain GI 8 SAE STANDARDS Eng
19. to you TemueUnt Formula t amp AUnt Nm Nmx AL A kgf m kgf m x LAL A kgf cm x L L A ft Ib x in lb x L L A A The length of the SST past the torque wrench drive L The length of the torque wrench VISE When using a vise put protective plates in the jaws of the vise to prevent damage to parts GI 13 Gl ELECTRICAL TROUBLESHOOTING TOOLS ELECTRICAL TROUBLESHOOTING TOOLS TEST LIGHT The test light as shown in the figure uses a 12V bulb The two lead wires should be connected to probes The test light is used for simple voltage checks and for checking for short circuits 1 4W or 3 4W Caution Using a bulb over 3 4W when checking the control unit may damage the control unit JUMPER WIRE A jumper wire is used to create a temporary circuit Con nect the jumper wire between the terminals of a circuit to bypass a switch Caution Do not connect a jumper wire from the power source line to a body ground this may cause burn ing or other damage to harnesses or electronic components VOLTMETER VOLTMETER The DC voltmeter is used to measure circuit voltage A voltmeter with a range of 15V or more is used by connect ing the positive probe red lead wire to the point where voltage is to be measured and the negative probe C black lead wire to a body ground POWER SOURCE LINE OHMMETER The ohmmeter is used to measure the resis
20. way radio observe the following precautions 1 Instail the antenna at the farthest point from contro modules 2 Install the antenna feeder as far as possible from the control module harnesses at least 30 cm 11 8 in 3 Ensure that the antenna and feeder are properly adjusted 4 Do not install a high powered mobile two way radio system FEEDER POWERTRAIN CONTROL WIRE MODULE HARNESS POWERTRAIN CONTROL MODULE AT LEAST 30 cm 11 8 in FARTHEST POINT AUDIO ANTITHEFT SYSTEM An audio with an antitheft function is optionally available Before removing the negative battery terminal or discon necting the audio power source obtain the code number and deactivate the audio antitheft system Refer to 1994 RX 7 Body Electrical Troubleshooting Q Q 3C 96963966 962 Manual TL LN TL HN LS tme my Mna TRL m asc GI 18 TIEDOWN HOOKS FRONT TOWING G TOWING Proper towing equipment is necessary to prevent dam age to the vehicle Laws and regulations applicable to vehicles in tow must always be observed As a general rule towed vehicles should be pulled with the driving wheels off the ground If excessive damage or other conditions prevent towing the vehicle with the driv ing wheels off the ground use wheel dollies With either automatic or manual transmission 1 Set the ignition switch in the ACC position 2 Place the selector lever or shift lever in N Neutral 3 Rel
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