'94 Mazda RX-7 Factory Service Manual
Contents
1. 15 minutes Does service code No 26 or 27 appear NO Metering oil pump control system OK ative battery cable for 20 se YES Replace metering oit pump D 15 D METERING OIL PUMP 2 Metering oil pump position sensor Position sensor resistance Is resistance between terminals Vo and E as specified Resistance 1 2 kQ Is resistance of terminal Vo E and Vo Vc as specified Resistance 0 4 12 kQ NO Replace metering oil pump Harness and connector continuity Is there continuity between position sensor and powertrain control module as shown Powertrain control module __ Position sensor Ve BRWM__ o a Vot e A YES Harness short circuit ls there short or ground between Vo and 3A of wiring harness YES Repair or replace wiring harness NO Control unit terminal voltage Turn ignition switch ON is there approx 1 4 2V indicated at termina 3A YES NO Repair or replace wiring harness NO Replace metering oil pump YES Replace powertrain control module Cancel memory of malfunctions by disconnecting negative battery cable for 20 se conds then reconnect it Does service code No 20 appear NO Position sensor operation Cancel memory of malfunctions by disconnecting negative battery cable for 20 se conds then reconnect it n l Warm up engine until coolant temperature reaches 80 C 176 F and let it idle 15 minutes Does s2. 14 PREPARATION 0 csr0200000 D 14 INSPECTION 0 0000i0c D 15 OIL PUMP D 17 DISASSEMBLY ASSEMBLY D 17 INSPECTION 2 0 nc nc cence ennenneens D 18 D i INDEX INDEX ENGINE OIL SPECIFICATION API SERVICE SG SH EC 0 ILSAC Mineral oil only TOTAL CAPACITY 4 9L 5 2 US qt 4 3 Imp except Ri model 5 4L 5 7 US at 4 8 imp Ri model 1 Oil filter 3 Oil pan Replacement page D 7 Removal Installation page D 10 2 Oil cooler 4 Metering oil pump Removal installation page D 8 Inspection page D 14 D 2 OUTLINE D OUTLINE SPECIFICATIONS Engine model 13B Turbo Lubrication system Type po o OT O Number of oor reni Diameter x width of rotor mm fin Control valve relief pressure kPafkgf cm2 psi Oil cooler Relief temperature C F 60 65 140 149 or below Relief pressure differential o o E kPa kgf cm psi 349 3 56 50 at 60 C 149 F Regulator valve relief pressure _ KkPaf kgf cm psi 780 8 0 110 Full flow paper element Oil filter Relief pressure differential __kPa kgf cm psi 98 1 0 14 Eccentric shaft bypass valve relief temperature C F 60 140 or below 4 9 5 2 4 3 except R1 model 5 4 5 7 4 8 R1 model Oil replacement L US qt Imp qt 3 6 3 8 3 2 dba Oil replacement with oil fi
3. min 5 Ifthe pressure is not as specified check for the cause and repair Refer to Troubleshooting Guide 6 Remove the SST 7 Apply sealant to the oil pressure sensor threads Do not allow sealant in the pressure sensor hole 8 Install the oil pressure sensor Tightening torque 11 15 N m 1 1 1 6 kgf m 8 11 ft lbf 9 Connect the sensor connecter D 5 D _ ENGINE OIL ENGINE OIL INSPECTION 1 Be sure the vehicle is on level ground 2 Warm up the engine to normal operating temperature and stop it 3 Wait for five minutes ea 4 Remove the dipstick and check the oil level and condition 5 Add or replace oil as necessary x x x x x x x Note The distance between the L and F marks on the dipstick represents 1 7 L 1 8 US qt 1 5 Imp qt REPLACEMENT Warning When the engine and the oil are hot they can badly burn Don t burn yourself with either 1 Warm up the engine to the normal operating temperature and siop it 2 Remove the oil filler cap and the oil drain plug 3 Drain the oil into a container 4 Install a new gasket and the drain plug Tightening torque 30 41 N m 3 0 4 2 kgf m 22 30 ft Ibf 5 Refill the engine with the specified type and amount of en gine oil Oil capacity L US qt Imp qt 4 9 5 2 4 3 except R1 model Total dry engine 5 4 5 7 4 8 R1 model Engine oil replacement 3 6 3 8 3 2 Engine oil replacement e with oil
4. filter 3 8 4 0 3 3 6 Refit the oil filler cap 7 Run the engine a few minutes and stop it 8 Recheck the oil level and add oil if necessary D 6 OIL FILTER D OIL FILTER REPLACEMENT 1 Remove the oil filter by using the oil filter wrench 2 Using a clean rag wipe the mounting surface of the en gine 3 Apply a small amount of clean engine oil to the rubber seal of the new filter 4 Install the oil filter and tighten it until the rubber seal con tacts the base and then tighten the filter an additional 1 1 6 turns by hand 5 Start the engine and inspect for leaks around the filter seal 6 Stop the engine and check the oil level add oil if neces sary Note The factory installed oil filter and the service part filter are different Service oil filter capacity 0 17 L 0 18 US qt 0 15 Imp qt D 7 D OIL COOLER OIL COOLER REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removai Note In case of two oil cooler are equipped LH oil cooler is shown Remove install RH oil cooler in same procedure 7 9 10 7N m s amp 80 110kgf cm 70 95 4in ibf aye i ar n CLIP REPLACE 7 9 10 7N m l 80 110kgf cm 70 95 4In Ibf 1 Light bezel 4 Oil cooler 2 Brake pipe air duct Removal Note aeaea page D 9 3 Oil cooler hoses 5 Air duct oil cooler Removal N
5. his file is available for tree 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 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 a 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 alarm conditions LUBRICATION SYSTEM INDEX ili D 2 OUTLINE sack iaia tp D 3 SPECIFICATIONS 0 D 3 TROUBLESHOOTING GUIDE D 4 OIL PRESSURE D 5 PREPARATION 00 D 5 INSPECTION 2 000000 00 D 5 ENGINE OIL D 6 INSPECTION 20ccscccceccoevccssess D 6 O REPLACEMENT cccseceeeeceeeess D 6 OIL FILTER culti D 7 REPLACEMENT c00000a gt D 7 OILCOOLER ji ils D 8 REMOVAL INSTALLATION D 8 OIL PAN SERE ATI D 9 PREPARATION aD 8 REMOVAL INSTALLATION D 10 OIL PRESSURE CONTROL VALVE D 13 REMOVAL INSTALLATION D 13 METERING OIL PUMP D
6. m 90 120kgf cm 79 104in Ibf Fill the engine with the specified amount and type of engine oil Refer to page D 6 D 12 OIL PRESSURE CONTROL VALVE _ D OIL PRESSURE CONTROL VALVE REMOVAL INSTALLATION 1 Remove the parts in the following order 1 Oil pan Refer to page D 9 2 Cap bolt and spring 3 Control plunger 2 Install in the reverse order 3 Check the engine for oil leakage and check the oil level INSPECTION 5 1 Check each part for damage and scoring Replace if nec essary 2 Measure the free length of the spring and if necessary replace it Free length 73 0 mm 2 87 in D 13 D METERING OIL PUMP METERING OIL PUMP PREPARATION SST 49 H018 9AT p 2 For 49 B019 9A0 oy For A pa diagnosis mo diagnosis of metering System Selector of metering Self Diagnosis i oil pump system Checker No i oil pump system Malfunctions related to the metering oil pump may be described as electrical component problems and me chanical component problems Electrical Component Related Problem 1 Check for service codes by using the SST Refer to section F 2 If service code No 20 26 27 or 37 appears check the metering oil pump following the diagnosis chart below Diagnosis Chart Service Code No 20 Metering oil pump position sensor Possible Cause Open or short circuit in position sensor wiring Open or short circuit in wiring between powertrain control module a
7. ervice code No 20 appear YES Replace metering oil pump NO Metering oil pump control system OK Mechanical Component Related Problem Excessive oil consumption may be caused by a metering oil pump malfunction Before replacing the metering oil pump refer to Oil leakage in the Troubleshooting Guide page D 4 and perform the electrical component inspection pages D 15 and D 16 D 16 aii inmana iii 1 Remove the oil nozzles from the rotor housing and the in take manifold 2 Verify that air passes in only one direction as shown If not so replace the oil nozzle OIL PUMP DISASSEMBLY ASSEMBLY t Disassemble in the order shown in the figure 2 Assemble in the reverse order of disassembly referring to Assembly Note 1 Snap ring 5 Screw 9 Front inner rotor 2 Rear outer rotor Assembly Note Assembly Note Assembly Note page D 19 sicuurcizit page D 18 stare page D 18 6 Body 10 Key 3 Rear inner rotor 7 Center plate 11 Shaft Assembly Note 8 Front outer rotor Redi page D 18 Assembly Note l oec E page D 18 D 17 METERING OIL PUMP OIL PUMP D Oil nozzle D 18 OIL PUMP INSPECTION 1 Inspect the oil pump parts for wear and damage Replace as necessary 2 Measure the clearance between the lobes of rotors by us ing a feeler gauge Standard clearance 0 03 0 12 mm 0 0012 0 0047 in Maximum 0 15 mm 0 0059 in 3 Measure the clearance between
8. ion Note page D 12 D 10 x 49 G017 SAO OIL PAN D Removal Note Engine mount bracket 1 Assemble the SST and connect the hook to the front en gine hanger 2 Remove the engine mounting nuts 3 Turn the bolt of the SST clockwise to lift the engine Crossmember 1 Remove the power steering oil hose bracket from the crossmember 2 oo the bolts and nuts arrows and the crossmem er Oil pan 1 Remove the engine mount brackets from the engine 2 Disconnect the oil level sensor connector and remove it from the harness bracket 3 Remove the oil pan mounting bolts Caution Pry tools can easily scratch the oil pan contact sur faces Prying off the oil pan can also easily bend the oil pan flange Refer to the following instructions before removing the oil pan 4 Insert a screwdriver only between the points shown in the figure to pry the oil pan loose D 11 MITA Steps After installation CRACKS OIL PAN Installation Note Oil pan 1 Remove all foreign material from the oil pan contact sur faces Caution If the bolts are reused remove the old sealant from the bolt threads Tightening bolts with old sealant on them may cause cracking inside the bolt holes 2 Apply silicone sealant to the contact surfaces of the oil pan and the engine side of the new gasket 3 Install the oil pan within five minutes of applying the seal ant Tightening torque 8 9 11 7N
9. lter Engine oil 7 L US q Imp at 3 8 4 0 3 3 Oil ileter ___0 19 0 20 0 17 _ L US at Imp at Service part 0 17 0 18 0 15 Grade ooo API Service SG SH ECI ILSAC Mineral oil only i Gu a Total dry engine L US at Imp at Temperature Engine oil Anticipated ambient temperature range before the succeeding oil change C F D 3 D TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE Possible Cause ation Page Engine hard starting Improper oil Replace D 6 insufficient oil Add oil D 6 Excessive oii Malfunction of metering oil pump mechanical component inspect D 14 consumption Faulty oif nozzie Inspect D 17 Oil leakage Repair Oil leakage Loose drain plug or damaged washer Tighten or replace Faulty seal at oil pan Repair Damaged front cover Replace Loose front cover boit or oil pan bolt Tighten Damaged sealing rubber O ring or front cover gasket Replace Malfunction of oil seal Replace Loose oil filter Tighten Loose or damaged oil level sensor or oil pressure gauge Tighten or replace Damaged oil cooler or oil cooler hose Replace Replace Repair Add oil Damaged oil tube Oil leakage Oii pressure drop Insufficient oil Worn or damaged oil pump gear Refer to Section C Clogged oil strainer Clean Maifunction of oil pressure control valve Replace Malfunction of oil pressure
10. nd position sensor Loose connection of position sensor or powertrain control module Open or shor circuit in wiring between powertrain contro module and stepping motor Loose connection of metering oil pump or powertrain con trol module Damaged stepping motor Insufficient powertrain control module voltage Open or short circuit in wiring between powertrain control module and stepping motor Loose connection of metering oil pump or powertrain con trol module Damaged stepping motor Position sensor inaccurate Insufficient powertrain control module voltage 37 Battery positive voltage drop Malfunction of charging system Refer to Section G Control Module Terminal Perform Inspection 2 page D 16 Perform inspection 1 26 Metering oil pump control system page D 15 Perform inspection 1 page D 15 27 Metering oil pump control system TY Ta pus pajo avi a a eG e ac oa 30 31 ac pepe ba fax ajepe AU STO O MIK i e E c A az ax av jar jan er Jan fat 40 ar 40 48 aP n Jar as SH jar 90 foe at 2021 aro fast v ri ate N els fujF ole D 14 Perni A METERING OIL PUMP D INSPECTION 1 Metering oil pump control system Stepping motor resistance Measure the resistance at the following terminals Is voltage as shown Beading must be A or B DS s er eje a o a Bi
11. ote page D 9 D 8 asta OIL COOLER OIL PAN D Removal Note Oil cooler hose l Remove the clip and disconnect the oil cooler hose us ing a drain pan to catch the oil Oil cooler 1 Remove the light bezel 2 Remove the mounting bracket nuts 3 Remove the oil cooler Steps After Installation Fill the engine with the specified amount and type of engine oil Refer to page D 6 OIL PAN PREPARATION SST 49 G017 5A0 l For De 49 G017 501 For i support of i support of Support engine engine Bar engine ia Part of 49 G017 5A0 49 G017 503 For 49 G017 502 For support of support of Support engine Hook engine P f i Part of 49 G017 5A0 art o 49 G017 5A0 D 9 D OIL PAN REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the undercover 3 Drain the engine oil 4 Remove in the order shown in the figure referring to Removal Note 5 Install in the reverse order of removal referring to Installation Note 37 53 3 7 5 5 27 39 99 117 10 0 12 0 8 9 11 7 Nem 90 120 kgf cm 79 104 in Ibf 7 8 10 7 Nem 80 110 kgf cm 70 95 4 in Ibf 75 93 7 6 9 5 55 69 18 26 1 8 2 7 14 19 N m kgf m it bf 1 Undercover 5 Crossmember 2 Stabilizer Removal Note page D 11 3 Engine mount bracket 6 Oil pan Removal Note page D 11 Removal Note sati page D 11 4 Steering gear box Installat
12. regulator valve Replace Clogged oil filter Replace Malfunction of eccentric shaft bypass valve Refer to Section C Excessive oil clearance between eccentric shaft Refer to Section C and main bearing Oil pressure gauge Oil pressure drop As described above does not work Malfunction of oi pressure gauge unit Refer to Section T Malfunction of electrical system Refer to Section T Oil level warning Insufficient oil Add oil indicator illuminates Malfunction of oil level sensor Refer to Section T when engine is Malfunction of electrical system Refer to Section T running Poor acceleration Malfunction of metering oil pump electrical component inspect TH Rough idle Malfunction of metering oil pump electrical component l Oil pressure becomes low when the engine is cold because the eccentric shaft bypass valve operates ONT n OIL PRESSURE D OIL PRESSURE Warning Continuous exposure with USED engine oil has caused skin cancer in laboratory mice Protect your skin by washing with soap and water immediately after this work PREPARATION SST 49 0187 280 For inspection of Gauge A oil pressure oil pressure INSPECTION 1 Disconnect the connector and remove the oil pressure sensor 2 Install the SST 3 Start the engine and let it warm up to operating tempera i ture ar 2 ATA 4 Run the engine at 3 000 rpm and note the gauge reading Oil pressure 340 kPa 3 5 kgf cm 50 psi
13. the outer rotor and the pump body Standard clearance 0 20 0 25 mm 0 0079 0 098 in Maximum 0 30 mm 0 0118 in 4 Inspect the side clearance of the rotors 1 Using a straightedge and a feeler gauge measure the depth of the rotor in the pump body 2 Measure the depth of the rotor sliding surface from the pump mounting surface 3 Add these two depth to obtain the side clearance 4 If not as specified grind or replace the pump body Standard end clearance 0 03 0 125 mm 0 0012 0 0049 in Maximum 0 15 mm 0 0059 in Assembly Note Outer rotor and inner rotor install the front and rear outer and inner rotors so that the tally marks on the rotors face the front housing OIL PUMP D Screw To prevent the screw from loosening stake it after instal lation D 19 ri
14. toS1 S3 Open 16 310 B2toS2 S4 Open 16 31 2 BitoS2 S4 76 319 Open B2t0S1 83 16 810 Open YES Harness termina voltage Turn ignition switch ON is battery positive voltage indicated at terminals B1 and B2 of harness with connector disconnected Replace metering oil pump B Repair or replace wiring harness Harness and connector continuity Is there continuity between stepping motor and powertrain control module as shown Stepping motor Powertrain contro module BO Jooo A Repair or replace wiring harness YES Powertrain control module terminal voltage stepping motor Turn ignition switch ON is battery positive volta e indicated atterminals 41 4J 4K OE and he XR 9 NO Repiace powertrain control module Note This test must be done with connector connected YES Powertrain control module terminal voltage position sensor Da Turn ignition switch ON is approx 1 4 2V indicated at terminal 3A NO YES Is approx 1 1V indicated at idle NO Replace metering oil pump YES Does voltage increase from approx 1 tV then return to approx 1 1V when accel NO erating and decelerating engine YES Position sensor operation Te Cancel memory of malfunctions by disconnecting neg conds then reconnect it Warm up engine until coolant temperature reaches 80 C 176 F and let it idle for
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