Mazda RX-7 1989 Service manual

•
•
RX-7
CONTENTS
TITLE
ENGINE
LUBLICATION SYSTEM
COOLING SYSTEM
-
FUEL AND EMISSION
CONTROL SYSTEMS
(NON- TURBO)
----- --- --- --- ---- ---
FUEL AND EMISSION
CONTROL SYSTEMS (TURBO)
- -- -
ENGINE ELECTRICAL SYSTEM
MANUAL TRANSMISSION
-- -- --
AUTOMATIC TRANSMISSION
(ELECTRONICALLY-CONTROLLED)
-- --- ---- - --
FRONT AND REAR AXLES
STEERING SYSTEM
BRAKING SYSTEM
-- -- -----
SUSPENSION
SECTION
1
2
3
4
5
7
9
10
11
13
BODY 14
-
BODY ELECTRICAL SYSTEM 15

c
-ENGINE
OUTLINE .................................................. C- 2
OUTLINE OF CONSTRUCTION ................. C- 2
STRUCTURAL VIEW ................................ C- 2
SPECIFICATIONS .................................... C- 4
INTERCHANGEABILITY ............................ C- 5
TENSION BOLT ........................................ C- 6
FRONT COVER ......................................... C- 7
ROTOR .................................................... C- 8
97UOCX 501
e
e

OUTLINE
OUTLINE OF CONSTRUCTION
The 13B in the 1989 RX-7 is basically the same as in the previous model but with some modli c:=:- _
improved engine performance.
Major changes
1. Rotor : Lighter, rotor recess shape change to increase compression ratio
2. Tension bolt : Strengthening ribs added
3. Front cover : Shape changed for new metering oil pump
4. Side housings : Inlet port erea enlarged
STRUCTURAL VIEW
HOUSING-RELATED PARTS
FRONT ROTOR HOUSING
FRONT HOUSING
FRONT OIL SEAL
REAR HOUSING
REAR ROTOR HOUSING
INTERMEDIATE
HOUSING
C-2
97UOCX·502
._)
·-

~ TING-RELATED
;:;'"'TA PARTS
BALANCE WEIGHT
ECCENTRIC PULLEY
REAR ROTOR
FRONT ROTOR
' •
DRIVE PLATE
COUNTER WEIGHT
FLYWHEEL
-.
C-3

SPECIFICATIONS
Item Model Turbo Non-Turbo
Eng1ne type Rotary eng1ne
~~
Displacement
cc (cu 1n)
6S4 X 2 (40.0 X 2)
Number of cyl1nders and arrangement
2 rotors. longitudinal
Combustion chamber type
Bathtub
Compression
rat10
9.0 1 9.7 1
A1r Induction 4 port
1nduct1on
6 port 1nduct1on
Pnmary 4S0 ATOC
32° ATOC
Open
Secondary
32° ATOC
Auxiliary 4S0 ATOC
Intake Pnmary
S0° ABOC
40° ABOC
Port t1m1ng
Close Secondary
soo ABOC 30° ABOC
Auxil1ary
80" ABOC \
Open
7S0 BBDC
Exhaust Close
48° ATOC
Fuel supply system EGI
lgn1t1on t1ming (w1th test connector
Tra1l1ng
(Green 1-p1n) grounded)
Lead1ng
20°
± 2 ' ATOC (REO)
l,~
so ± 1o ATOC (YELLOW)
Idle speed (w1th test connector (Green 1-pln)
grounded) rpm 750 ± 25
97UOCX 504
C-4

•
INTERCHANGEABILITY
::: ,.,,ng chart shows interchangeability of major components of the previous model and the 1989 mode'
... ousmg-
·~ ated
;:.a r1S
X Not interchangeable
Part
Front rotor hous1ng
Rear rotor hous1ng
Front hous1ng
intermed1ate housing
Rear housing
nner
seal1ng rubber
Outer sealing rubber
Front cover
Orl pan
Tens1on bolt
i
. - ---1
I
+
;; :~at1ng- ::ccentnc shaft
-~ a~ed
=~~s Rotor
~~pex seal
J
3a',ance weight I
J I pump dnve sprocket -~· .
: :centr1c shaft pulley t
'C =centnc shaft bypass valve - -
Sde seal
:::orner seal
-1
~ . ·ey lock bolt
~ . :. heel (MIT)
l
I,
•· beanng (MIT)
.1ter we1ght (A/T)
Interchangeability
X
X
0
X
0
X
0
X
0
0
0
X
0
X
0
0
X
0
X
C-5
Remark
• Knock sensor boss added
• Inlet port area enlarged
• Shape changed to Incorporate new metw
tng Oil pump
• Ribs added to center of shank
• We1ght reduct1on
• Combustion chamber shape changed
• Shape changed
• Shape changed
• Shape changed
• We1ght reduct1on
• Shape changed
' •
We1ght reduct1on

TENSION BOLT
OTHERS
(}1
No.18 BOLT
NOTE
No.1? SOL
T IS LONGER THAN
OTHERS. THERE IS AN IDEN-
TIFICATION MARK.
T
lllllllllllllllllllllllllllllll
STRENGTHNING RIBS
128 ± 2mm (5.04 ± 0.08 in)
HEAT-SHRINK PROTECTOR
No.18 BOLT
97UOCI 506
The strength of the tension bolts 1s increased by addit1on of strengthening ribs in the middle of the shank.
The tension bolt installed into the No.18 hole differs from others
in that it is not fully enclosed. lead1ng to
transmiss1on of eng1ne noise. To reduce this noise. the heat-shrik protector is used on the bolt where 1t goes
through the intermediate housing boss. The No.18 bolt
is supplied as an assembly (bolt w1th washer and
protector).
If the bolt is reused and the protector is damaged, replace the protector. The protector 1s easily
shrunk w1th a l1ghter or match.
C-6
...

, .•
~.
•
FRONT COVER
FRONT COVER GASKET
FRONT COVER
~BACKUP RING
0-RING
~ · 989 RX-7 front cover is changed to incorporate a new metering oil pump.
:::::ded between the front cover and front housing for improved sealing.
C-7
97UOCX 507

ROTOR
TURBO
~
~
\
RIBS A
A~
/J
10.9mm (0.43 in)
I
NON-TURBO
c--~~
v
~
RIBS A A
~-
r---/1
8.8mm (0.35 in)
97UOCX 508
The rotor in the 1989 RX-7 is lighter and provides a higher compression ratio (9.0 : 1 for turbo model and
9.7 : 1 for non-turbo model) than the previous engine.
These improvements results
in a engine with more power and torque.
The rotor ribs are redesigned for increased strength.
The combustion chamber rotor recess
1s made more uniform by utilizing a mechanical cutting process.
The rotor for turbo and non-turbo engines are distinguished by the rotor recess shape.
C-8
,_ 4

D
...
LUBRICATION SYSTEM
OUTLINE .................................................. D- 2
OUTLINE OF CONSTRUCTION ................. D- 2
STRUCTURAL VIEW ................................ D- 2
SPECIFICATIONS .................................... D- 3
INTERCHANGEABILITY ............................ D- 3
METERING OIL PUMP ............................... D- 4
OUTLINE ............................................... D- 4
OPERATION ........................................... D- 5
FAIL-SAFE FUNCTION ............................. D- 5
SERVICE POINT ....................................... D- 6
OIL FILTER ............................................ D- 6
97UODX 501
-
-

OUTUNE
OUTLINE OF CONSTRUCTION
-~e lubncation system of the 1989 RX-7 is basically the same as the previous model. but some improve-
"lents have been made as described below.
1 A new electronically controlled metering oil pump is adopted instead of the previous mechanical metering
oil pump for reduced oil consumption and improved reliability.
2 A smal!-size oil filter is used and its installation procedure is different.
STRUCTURAL VIEW
TURBOCHARGER
0-2
MANIFOLD
OIL NOZZLE
HOUSING

SPECIFICATIONS
Items Engine model
Lubncat1on system
Type
011 pump
1
Number of rotors
1 D1ameter x w1dth of rotor
Control valve relief pressure
mm (1n)
kPa (kg/cm2. ps1)
Oil cooler
Type
Rel1ef temperature oc (°F)
Rel1ef pressure dlfferent1al kPa (kg/em'. ps1)
Regulator valve rel1ef pressure kPa (kg/em'. ps1)
Type
Oil filter
Rel1ef pressure d1fferent1al kPa (kg/em'. ps1)
Eccentnc shaft bypass valve rel1ef temperature oc (°F)
Oil capaCity
Total (dry eng1ne)
l1ters (US qt. Imp qt)
011 pan
Oil cooler
liters (US qt. Imp qt)
l1ters (US qt Imp qt)
\ F
011 filter , actory-1nstalled
I
l1ters (US qt Imp qt) i Serv1ce parts
Turbo
Force-fed
Trocho1d
2
Non-Turbo
50 X 17.5 (1 97 X 069) 50 X 12.5 (1.97 X 0.49)
1.079 (11.0. 156)
A1r cooled. w1th bypass valve
60-65 (140-149) or below
349
(3 56. 50) at 60°C (140"F)
490 (5.0. 71)
Full flow. paper element
98 (1.0. 14)
60 (140) or below
5.8 (6 1 5.1)
4.4 (4.7. 3 9)
0.85 (0.90. 0 75)
0.19 (0.20 0 17)
0.17 (0.18. 0 15)
Eng1ne oil (API serv1ce) Fuel eff1c1enr· SF (M1neral oil only)
_____ _[_________ ---- ___ _j
97UODX 507
INTERCHANGEABILITY
The following chart shows interchangeability of major components of the previous model and the 1989 model.
Interchangeable X Not Interchangeable
Part Interchangeability Remark
011 pump
Oil pump unchanged
Baffle plate for turbo model el1m1nated
rl1eterlllg oil pump
X Shape
changed
0 I f1lter
Small-s1ze filter used
Shape changed
--1ous1ng oil nozzle Shape cr1anged
J _c_o_o_le_r ______________ ~ ______________________________ j
97UODX 503
0-3

METERING OIL PUMP
OUTLINE
An electronically controlled metering oil pump is used instead of the previously used mechan1cal metering
oil pump for reduced oil consumption. This new metering oil pump is controlled by the eng1ne control unit. ... ~
The ECU bases it calculation of engine oil needs on the input from various sensors.
It then sends a pulse signal to control the oil discharge amount according to engine speed, eng1ne coolant
temperature and intake air amount (load condition).
The same metering
oil pump is used for turbo and non-turbo engines, but the oil nozzle plumbing 1s different
TURBO
HOUSING OIL NOZZLE
MANIFOLD OIL NOZZLE
NON-TURBO
0-4
~
I
NON-TURBO
97UODX·504

OPERATION
The oil discharge mechanism in the new electronically controlled metering oil pump is the same as that in
the previous mechanical metering oil pump. The plunger and differential plunger are driven through the driv-
ing worm, which
is driven by the eccentric shaft.
The
oil discharge amount is controlled by movement of the control p1n.
The plunger rides against the taper of the control pin. As the p1n moves up or down, the plunger stroke
changes to control the
oil discharge amount.
Stepping motor operation
is monitored by the pos1t1on sensor, which results in the engine control unit setting
the optimum
oil discharge for all driving conditions.
CONTROL PIN f
OIL
FAIL-SAFE FUNCTION
STEPPING MOTOR
/
SUB-PLUNGER
DIFFERENTIAL PLUNGER
DRIVING WORM
97UODX 505
If the engine control unit senses a malfunction of the stepping motor or posit1on sensor. fail-safe function
takes place.
The engine control unit fixes the control pin to its lowest compensation step, and oil is discharged in propor-
tion to engine speed only without any load compensation.
The vehicle can be driven normally as long as the oil injection needs are within the lowest compensation
step range.
' the oil injection needs exceed the lowest compensation step range. fuel injection is restricted to limit the
~1gine speed and resultant oil injection requirements.
D-5

SERVICE POINT
OIL FILTER
The 1989 RX-7 has a small-size oil filter. The factory-installed oil filter differs from the service parts oil filter.
The service oil filter is the same as that used for the Mazda 323 B-series engine. ' .....
Oil filter capacity
ctory 1nstalled
rvice part
- --·-----·-----
Replacement
019 (0.20, 0.17)
0.17
(0 18. 0.15)
liters (US qt, Imp qt)
_,]
97UODX 508
1. Remove the oil filter with a suitable wrench.
2. Use a clean rag to wipe clean the mounting surface on the
engine.
3. Apply a small amount of clean engine oil to the rubber seal
of the new filter.
4. Hand tighten the oil filter until the rubber seal contacts the
base, and then tighten the filter an additional 1-1/6 turn with
a wrench.
5. Start the engtne and inspect for leaks around the filter seal. · .J
6. Check the oil level and add oil as necessary.
0-6

E
COOLING SYSTEM
OUTLINE .................................................. E- 2
OUTLINE OF CONSTRUCTION .................. E- 2
STRUCTURAL VIEW ................................ E- 2
SPECIFICATIONS .................................... E- 3
INTERCHANGEABILITY ............................ E- 3
COOLING FAN .......................................... E- 4
WATER PUMP
.......................................... E- 5
THERMOSTAT .......................................... E- 6
RADIATOR ............................................... E- 7
97UOEX 501
-

OUTLINE
OUTLINE OF CONSTRUCTION
The cooling system of the 1989 RX-7 is basically the same as the previous model but certain improvements
have been made as described below.
1. The number of cooling fan blades is increased from 8 to 10 for improved cooling performance.
2. In conJunction with the cooling fan modification, the shape of the water pump is changed for improved rigidity.
3. A new radiator with a filler cap body is adopted for improved serviceability.
4. In conjunction with the radiator modification, the thermostat cover and thermostat gasket shapes are changed.
STRUCTURAL VIEW
FROM HEATER
RESERVOIR
(/
fj
ELECTRIC
COOLING FAN FAN RELAY DRAIN PLUG
E-2
THERMOSTAT
~
RADIATOR CAP
FILLER CAP BODY
WATER PUMP
97UOEX-502

nts
lity.
ed.
-
)02
SPECIFICATIONS
Item Engine
mode~
Cool1ng method
Coolant capac1ty W1th heater liters (US qt.
Imp qt)
/Vater pump
Tl1ermostat
Rad1ator
'ller cap
Cool1ng fan
: (;CtriC COOling
Type
Pulley rat1o (speed)
Type
Open1ng temperature
Full ope'l temperature
Full open l1ft
[ Type
Relief pressure
Type
Number of blades
Outer d1ameter
Type
i Capac1ty
Number of blades
Outer d1ameter
INTERCHANGEABILITY
°C (°F) i
I
oc (oF) i
mm (1n)
I
kPa (kg/cm
2•
ps1)
mm (1n)
w
mm (1n)
Turbo Non-Turbo
Water-cooled, forced c1rculat:o'l
8.7 (9.2 7.7) 7.3
(7 7 c ~
Ce'ltnfugal
1 1.22
Wax. bottom bypass
80.5-83.5 (177 -182)
95 (203)
8-10 (0.31-0.39)
Corrugated f1n
74-103 (0.75-1.05. 11-15)
Thermo-modulated
10
390 (15 35)
Electncal
90
5
255 (10.04)
~. ;co following chart shows the major components interchangeability between the previous model c:·
· ?39 model.
··_?•changeable X
Not Interchangeable
Parts Interchangeability Remark
X
Shape changed
· ":Jstat X Rubber gasket used
:
c::or
X
Shape changed
: :::Jr cap
c
'lQ fan X
Blade number Increased
··:: ::ooling fan 0
E-3

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COOLING FAN
FAN DRIVE
The thermomodulate cooling fan used in the 1989 RX-7 has 10 blades and a s1ngle bear1ng 1nstead of 8
blades and double bearing of the previous model, which result in improved cooling performance. The cool-
ing fan drive characteristics is the same as the previous model but the fan-dr1ve 1s not Interchangeable be-
cause the water pump shaft bearing mounting diameter is larger.
E-4
•_/