Mazda 1983 RX7 Manuals

Mazda 1983 RX7 Manuals

Manuals and User Guides for Mazda 1983 RX7. We have 1 Mazda 1983 RX7 manual available for free PDF download: Service Manual

Mazda 1983 RX7 Service Manual

Mazda 1983 RX7 Service Manual (459 pages)

Brand: Mazda | Category: Automobile | Size: 4 MB

Table of Contents

Cruise Control System
2
Description
2
Operation
2
Main/Control Switch
2
Testing
3
Wiring Diagram
4
Instrument Panel - Standard
5
Description and Operation
5
Gauges
5
Removal and Installation
6
Instrument Cluster
6
GLC Hatchback Removal/Installation
6
GLC Wagon Removal/Installation
6
Combination Switch
7
Gauge Testing Needle Locations
7
Wiper/Washer System
8
GLC Wagon Operation
8
Wiper Motor Testing
8
All Other Models
8
Front Wiper Motor Assembly
9
Rear Wiper Motor Assembly
9
Wiper Switch
9
Mazda GLC Hatchback Wiring Diagram
10
Mazda GLC Wagon Wiring Diagram
10
Mazda RX7 Wiring Diagram
11
Mazda B2000 and B2200 Wiring Diagram
11
Mazda 626 Front Wiper Wiring Diagram
12
Mazda 626 Rear Wiper Wiring Diagram
13
Electrical Component Locator
14
RX7 Component Locator Chart
14
Miscellaneous Components
14
Control Units
15
Coolant Level Control Unit
16
Control Processing Unit
16
Cruise Control Unit
16
Emission Control Unit
17
Oscillator Control Unit
17
Stop Light Checker
18
A/C Relays
18
Choke and Check Relay
19
Horn Relay
19
Hot Start Relay
20
Power Antenna Relay
20
Sending Units/Sensors
21
Sending Units/Sensors
22
Heat Hazard Sensor
23
Oil Level Sensor
23
Oil Pressure Sending Unit
24
Oil Thermo Sensor
25
Throttle Sensor
25
Washer Fluid Level Sensor
25
Solenoids/Solenoid Valves
26
Leading Vacuum Control
27
Leading Vacuum Control Solenoid, Valve
28
Rear Hatch Release Solenoid
28
Relief Solenoid Valve
28
Shutter Solenoid Valve
30
Trailing Vacuum Control Solenoid
31
Back-Up Light Switch
32
Brake/Stop Light Switch
33
Clutch Switch
33
Coolant Temperature Switch
34
Inhibitor Switch
34
Kickdown Switch
34
Parking Brake Switch
34
Alternator and Regulator
35
Application
35
On-Vehicle Test
35
Overhaul Disassembly
37
Diode Assemblies
37
Rotor Field Continuity
37
Component Replacement
38
Reassembly
38
Rotor Field Coil Ground
38
Stator Coil Ground/Continuity
38
Exploded View of Mitsubishi Alternator
39
Fuse and Flasher Locations
40
1983 Fuse Blocks, Flashers and Relays
40
Component Location
40
Fuses and Articles Breakers
42
Fuse Panel Location
42
Fuse Panel and Fuse Block Identification
42
Fuses and Circuit Breakers
42
Cautions and Warnings
44
Brake Pad Wear Indicator
44
Headlight Retractor
44
Air Bag System
44
Ignition System
45
Schematic of RX7 Ignition System
45
Operation
45
Adjustments
46
Reluctor-To-Pick-Up Coil Air Gap
46
Ignition Timing
46
High Tension Wire Resistance Check
47
Ignition Coil Resistance Check
47
Pick-Up Coil Resistance Check
47
Pick-Up Coil Operation Check
48
Igniter Check
48
Ohmmeter Hookup for Pick-Up Coil Resistance Check
48
Test Lamp Hookup for Checking Ignitor Operation
48
Overhaul Reassembly
49
Disassembled View of RX7 Mitsubishi Distributor
49
Starter - Hitachi/Mitsubishi
50
Mitsubishi Starter Application Table
50
Starter Performance Tests
50
Solenoid Tests
51
Load (Lock Torque) Test
51
Pull-In Coil Test
51
Hold-In Coil Test
52
Connections for Conducting Solenoid Pull-In Test
52
Connections for Conducting Solenoid Hold-In Test
52
Overhaul Disssasembly
53
Return Test
53
Connections for Conducting Return Test
53
Cleaning and Inspection
53
Bench Tests
54
Brush Spring Tension Table
54
Minimum Brush Length Table
54
Commutator
54
Overrunning Clutch Assembly
55
Pinion Gear Clearance
55
Pinion Case Bearing
55
Measuring Pinion Edge-To-Pinion Stopper Clearance
55
Disassembled View of Typical Mitsubishi Conventional Starter
56
A/C System General Diagnostic Procedures
57
Altitude Pressure Variations Table
57
Altitude Vacuum Variations Table
57
Preparation for Testing
58
Air Conditioning System Performance Check Table
58
Ambient Temperature /Pressure
59
Air Conditioning Diagnosis with Gauges for Systems
60
Evaporator Temperature/Pressure A/C Chart
60
A/C System Precautions
62
Before Opening the System
62
Discharging A/C System
62
Disconnecting Lines and Fittings
62
Using R-12 Refrigerant - Safety Precautions
63
Using Individual R-12 Cans
63
Multi-Can Dispensing Valves
63
Can Tap Installation Flat Type Seal Cans
63
Screw Type Seal Cans
64
Connecting Lines and Fittings
64
Placing System in Operation
64
Compressor Removal Informtaion - Isolation Method
64
Compressor Removal Information - Discharge Method
65
Transmission Removal and Installation
66
Pickup Removal/Installation
66
GLC (RWD) Removal
66
GLC (RWD) Installation
67
GLC (FWD) Removal/Installation
67
Transmission Servicing - A/T
68
Identification
68
Lubrication
68
Fluid Level
68
Brake Band Adjustment
69
Kickdown Switch and Downshift Solenoid
69
Transaxle
69
Shift Linkage
70
Selector Lever Handle Adjustment
70
Neutral Safety Switch
70
Adjusting Neutral Safety Switch on RX7 Transmissions
70
Brake System
72
Rear Drum Brake Shoes
72
Adjusting Rear Brake Shoe-To-Drum Position
72
Brake Pedal Height Adjustment
73
Parking Brake
73
Brake Warning Light
73
Front Disc Brake Pads Removal and Installation
73
Rear Disc Brake Pads
74
Front Disc Brake Caliper
74
Rear Brake Caliper
74
Front Disc Brake Rotor
75
Rear Brake Drum
75
Exploded View of GLC Wagon Rear Brakes
75
Overhaul
76
Rear Brake Shoes
76
Master Cylinder
76
Power Brake Unit
76
Exploded View of Pickup Front Disc Brake Caliper
77
Exploded View of RX7 Front Brake Caliper
77
Rear Disc Brake Caliper
77
Proper Installation of Conical Spring and Adjusting Bolt
78
Wheel Cylinders
79
Master Cylinder
79
Exploded View of Wheel Cylinder
79
Power Brake Unit
80
Exploded View of Typical Master Cylinder
80
Exploded View of Typical Power Brake Unit
81
Torque Specifications
82
Disc Specifications
82
Drum Specifications
83
1.1L Rotary
84
Engine Coding
84
Engine Removal and Installation
84
Engine Identification
84
Exploded View of Rotors and Eccentric Shaft Assembly
85
Oil Pump Drive and Sprocket Removal
86
Loosening Sequence of Tension Bolts
87
Inspection and Overhaul
88
Front, Intermediate and Rear Housings
88
Extracting Tubular Dowels from Engine
88
Straightedge Positions for Checking Housing Distortions
88
Side Seal Step Wear Table
89
Measuring Housing Wear with Dial Indicator
89
Checking Side Seal Step Wear
89
Oil Seal Step Wear
90
Rotor Housing
91
Stationary Gear Slot and Dowel Alignment
91
Measuring Rotor Housing for Distortion
91
Rotors
92
Rotor Oil Seal
92
Rotor Housing Thickness Check Points
92
Measuring Point of Oil Seal Protrusion
92
Rotor Bearing Replacement
93
Apex Seal
93
Pressing Rotor Bearing from Rotor
93
Measuring Apex Seal Height
93
Side Seal
94
Corner Seal
94
Apex Seal Warpage
94
Measuring Free Height of Apex Seal Spring
94
Eccentric Shaft
95
Checking Corner Seal Groove Measurement
95
Measuring Clearance of Apex, Side and Corner Seals
95
Oil Seals Reassembly
96
Installing Oil Seal Spring on Rotor
96
Apex, Corner and Side Seals
97
Installing Front Rotor
97
Installing Assist Piece on Apex Seal
97
Installing Eccentric Shaft
98
Installing Front Rotor Housing
98
Positioning Rotor Apex for Reassembly
98
Applying Sealing Agent to Rotor Assembly
98
Installing Protectors for Inner Sealing Rubbers
99
Positioning Inner Sealing Rubber
99
Installing Intermediate Housing
100
Installing Rear Rotor and Housing
100
Installing Rear Housing
100
Tightening Tension Bolts
100
Flywheel Counterweight Installation
101
Eccentric Shaft End Play Adjustment
101
Tightening Sequence of Tension Bolts
101
Measuring Eccentric Shaft End Play
102
Engine Oiling
103
Crankcase Capacity
103
Installing Front Cover and Eccentric Shaft Pulley
103
Installing Oil Strainer and Oil Pan
103
Oil Filter
104
Normal Oil Pressure
104
Engine Oiling System
104
Oil Pump
105
Mazda RX7 Engine Oiling System
105
Measuring Oil Pump Drive Chain Slack
105
Metering Oil Pump
106
Exploded View of Oil Pump Assembly
106
Adjusting Metering Pump Control Rod
106
Oil Cooler
107
Engine Cooling
107
Thermostat
107
Water Pump
107
Pressure Cap
107
Engine Specifications
108
Exploded View of Water Pump
108
Rotor Specifications
109
Apex Seal Specifications
109
Side Seal Specifications
110
Shaft and Rotor Bearing Specifications
110
Corner Seal Specifications
110
Oil Seal Specifications
110
Port Timing Specifications
111
A-Engine/Vin ID
112
Model Identification
112
VIN Code ID Explanation
112
VIN Code Identification
112
Air Injection System
114
Air Pump Test
115
Check Valves Test
115
Air Control Valve Test
115
Relief Solenoid Valve Test
116
Hose Arrangement for Checking
116
Relief Solenoid Valve Signal Check Test
117
Testing Relief Solenoid Valve
117
Switching Solenoid Valve Signal Check Test
118
Testing Relief Solenoid Valve Signal
118
Heat Hazard Sensor Test
119
Testing Switching Solenoid Valve
119
Testing Heat Hazard Sensor
120
Auxiliary Control Device
121
Control Unit
121
Terminal Locations of Control Unit and Throttle Sensor
121
Choke Relay
122
Choke Switch
122
Choke Relay Terminal Locations
122
Choke Switch Terminal Locations
122
Water Temperature Switches
123
Control Unit Testing
124
Carburetor - NIKKI 4-BBL
125
Float Level
125
Float Drop
125
Float Level Adjustment
125
Choke Linkage
126
Choke Valve Opening Angle
126
Float Drop Adjustment
126
No. 2 Choke Diaphragm
127
Choke Diaphragm Operation
127
Checking Choke Delay Valve Operation
127
Choke Valve Opening Angle Adjustment
127
Checking Automatic Choke Release
128
Checking Carburetor Heater
128
Hot Start Assist Cable
128
Throttle Opener
129
A/C Models Only
129
Hot Start Assist Cable Adjustment
129
Throttle Opener Adjustment
129
Checking Altitude Compensator
130
Accelerator Cable Adjustment
130
Adjusting Accelerator Cable and Pedal Height
130
Removing Jets and Air Bleeds
131
Adjustment Specification
132
Choke - Electric Assist
133
Choke Return System
133
Hot Start Assist System
133
Choke Return and Hot Start Assist Systems
134
Engine Temperature Indication for Release of Choke Knob
134
Choke Magnet
135
Hot Start Assist Relay
135
Choke Switch Terminal Numbering
135
Hot Start Assist
136
Adjusting Hot Start Relay Cable
136
Deceleration Control System
137
No.1 Anti-Afterburn Valve
137
Operation
137
No.2 Anti-Afterburn Valve
138
Testing No. 1 Anti-Afterburn Valve
138
Throttle Sensor
138
Testing Throttle Sensor
139
Shutter Solenoid Valve Signal Check
140
Testing Shutter Solenoid Valve
140
Coasting/Shutter Valve
141
Dashpot
141
Testing Shutter Solenoid Valve Signal
141
Emission Application
143
Emission Control Device Applications
143
Abbreviation Definitions
143
Fuel Evaporatijn System
145
Air Vent System
145
Mazda RX7 Check and Cut Valve
145
Check and Cut Valve
146
Evaporative Line Check
146
Mazda RX7 Air Vent and Fuel Evaporation System
146
Air Vent Solenoid Valve
147
Maintenance
147
Fuel Pump - Electric
148
Pressure Test
148
Volume Test
148
Fuel Pump
149
Hot Idle Compensation System
150
Mazda Hot Idle Compensator Valve
150
Idle Compensation System
151
Idle Compensator Operation
151
Altitude Compensator Operation
151
Throttle Opener Operation
151
Idle Compensator Test
152
Altitude Compensator Test
152
Air Conditioner Solenoid Valve Test
153
Air Conditioner Solenoid Valve Signal Check Test
154
Air Conditioner Relay Test
154
Throttle Opener Test
155
Air Conditioner Relay Terminals
155
PCV System
156
Piston Engines
156
Rotary Engines
156
Diesel Engine
156
Piston Engines Testing
157
Rotary Engines Testing
157
B2000 Pickup Crankcase Ventilation System
157
RX7 Rotary Engine Purge Valve
158
GLC and 626 Crankcase Ventilation System
158
B2200 Diesel Pickup Crankcase Ventilation System
158
Spark Control System
159
Vacuum Control Solenoid Valve
159
Vacuum Control Solenoid Valve Signal Check
159
Testing Vacuum Control Solenoid Valve
160
Tune-Up - Rotary
161
Engine Identification
161
Engine Compression
161
Compression Specifications
161
High Tension Wire Resistance
162
Distributor Adjustment
162
Ignition Timing Adjustment
162
Firing Order and Distributor Rotation
162
Tune-Up - Rotary
162
Idle Speed and Mixture
163
Connecting Timing Light
163
Ignition Timing Mark Location
163
Idle Speed and Mixture Specifications
164
Carburetor Adjusting Screw Locations
164
Cold (Fast) Idle RPM
165
Servicing
165
Emission Control
165
Specifications
165
Starter Specifications
166
Service Specifications
166
Vacuum Diagrams
168
Mazda RX7 Rotary Engine Vacuum Diagram
169
Maintenance Information
170
VIN Location
170
Maintenance Service Information
171
Severe and Normal Service Definitions
171
Service Point Locations
172
Information Label Locations
175
Information Label Locations
176
Service Labor Times
176
Lubrication Specifications
176
Fluid Capacities
177
Wheel and Tire Specifications
177
Tire Inflation Specifications
178
Wheel Tightening
178
Battery Specifications
178
Supplemental Restraint System (Air Bag)
178
Anti-Lock Brake System
179
Battery Warning
179
Replacing Blown Fuses
179
Catalytic Converter
179
Coolant
180
Electrostatic Discharge Sensitive Parts
180
Fuel System Service
180
Halogen Bulbs
180
Radiator Cap/Fan
181
Turbocharged Models
181
Fuses and Circuit Breakers
182
Emission Control System
182
Fuse Panel Identification (1983-85)
183
Fuse Block Identification (1983-85)
183
Fuse Panel and Fuse Block Identification (1986-90)
184
Fuse Panel and Fuse Block Identification (1991)
186
Scheduled Services
189
Cautions and Warnings
189
Anti-Lock Brake System
189
Radiator Fan
192
Severe Service Requirements (Perform W/Service Schedules)
196
Normal Maintenance Service Schedules
198
Service Indicator and Warning Lights
225
Dash Gauges and Warning Lights
225
Transmission Removal and Installation - M/T
227
Transmission Servicing - M/T
228
Service Intervals
228
Fluid Type
228
Linkage
228
Clutch Assembly
229
Release Bearing and Fork
230
Exploded View of RWD Clutch Assembly
230
Clutch Master Cylinder
231
Clutch Slave Cylinder
231
Clutch Cable
231
GLC Wagon Clutch Cable Assembly
231
Pilot Bearing
232
Flywheel
232
Exploded View of Clutch Master Cylinder
233
Clutch Pedal Height
234
Clutch Pedal Free Play
234
Exploded View of Clutch Slave Cylinder
234
Clutch Pedal Height Specifications
235
Clutch Adjustment Locations
235
Drive Axle
236
Axle Ratio and Identification
236
Exploded View of Mazda Rear Axle Assembly
236
Axle Shafts and Bearings
237
Exploded View of Axle Shaft Assembly
237
Differential Carrier
238
Exploded View of Axle Shaft Assembly for Pickups
238
Case Assembly
239
Drive Pinion Depth
240
Dummy Pinion Shaft and Gauge Block
240
Pinion Depth Adjusting Shims
241
Measuring Drive Pinion Installed Height
241
Initial Pinion Nut Torque
242
Pinion Bearing Preload
242
Installing Drive Pinion Bearing Collapsible Spacer
242
Axle Assembly Specifications
243
Backlash and Side Bearing Preload
243
Adjusting Differential Bearing Preload
243
Steering Column
245
GLC Wagon Steering Column
246
Torque Specifications
246
Steering Column Switches
247
Steering Wheel and Combination Switch
247
Ignition Switch
247
Typical Mazda Steering Wheel Assembly
247
Steering Lock
248
Exploded View of Ignition Switch
248
Steering Gear - Manual
249
Exploded View of Steering Gear Assembly
250
Steering Linkage
251
Worm Bearing Preload
252
Sector Shaft End Play
252
Steering Gear Backlash
252
Checking Sector Shaft Adjusting Screw End Clearance
252
Final Worm Bearing Preload Table
253
Suspension - Front
254
Wheel Bearing Adjustment
254
Ball Joint Checking
254
Wheel Bearing Removal and Installation
255
Lower Control Arm
255
Strut Assembly
255
Front Suspension
255
Strut Reservoir Volume Table
256
Suspension - Rear
258
Coil Spring Removal and Installation
258
RX7 Rear Suspension Assembly
258
Shock Absorber
259
Upper/Lower Links and Watt Links
259
Stabilizer Bar
259
Jackking and Hoisting
261
Frame and Underbody
261
Outerbody
261
Floor Jack, Floor Hoist and Vehicle Jack
261
B2000 and B2200 Lifting Points
262
GLC and 626 Lifting Points
262
GLC Wagon Lifting Points
262
RX7 Lifting Points
263
Pre-Alignment Checks
264
Wheel Alignment Specifications and Procedures
265
Tire Inflation
265
Caster
265
Macphearson Strut Support Table
265
Camber
266
Toe-In
266
GLC FWD and 626
266
Wheel Alignment Specifications Table
267
GLC and 626 Star Wheel Adjustment
267
1.3L Eng no Start/Blown Fuse
269
Condition and Cause
269
Repair
269
View of Wiring Harness
269
Acceptable Battery Drain
270
Technical Service Bulletin
270
Current Draw from the Battery
270
Current Draw Amperage
270
Test Procedures
270
Testing Currant Draw
271
Alternator/Regulator Test Process/Replacement
272
IC Regulator Checking Procedure
272
Parts Information
272
Exploded View of Alternator
272
Article Beginning
272
Repair Procedure
273
Location of "F" Terminal
273
Proper Location of Insulators
273
Audio System Troubleshooting Procedures
274
Battery Removal/Install Wire Clip Warning
276
Battery Clamp Bolt and Nut
276
Fusible Link Reference Chart
277
Service Information
277
High Pitch Buzzing Noise at Dash: Remove Oscillator
279
Technical Information Tip
279
Keyless Switch Speed Nut Information
280
Speed Nut for Ignition Key Switch
280
Securing Key-Less Switch with Speed Nut
280
Miscellaneous Blown Fuses/Electrical Problems
281
View of Rear Wiring Harness
281
Rear Window Defroster Grid Line Repair Procedure
282
Resin Application Location
282
Warranty Information
283
Revised Wiper Link Bushing
284
1981-85 RX7 Wiper Link
284
Turn Signal Doesn't Cancel
285
Turn Signal Switch Cancel Cam
285
Steering Wheel Removal
285
Turn Signal Cancel Cam
286
Removing Cancel Cam from Switch
286
Torque Specification
286
Aligning Cancel Cam Tabs
287
1.2L Eng Modified A/C Compressor Bracket Instruction
288
A/C Compressor Bracket Installation
288
VIN of Production Change
288
Installation of A/C Compressor Bracket
288
Article Beginning
288
Parts Information
289
A/C Lite DIM/Not On-Wire Harness Connector
290
Air Conditioner Indicator Light
290
A/C Indicator Light Harness Routing
290
RX7 A/C Accessory Connectors
291
Correct Freon Charge Warning Specs
292
Refrigerant Charge Service
292
Quick Visual Check
292
A/C Charging Sight Glass Symptoms
292
Heating System Troubleshooting
293
Heating and Defroster Troubleshooting Manual
293
Using this Manual
294
Climate Control System
294
Customer Comment Sheet
295
Check Sheet
297
Heater Concern
297
Diagnostic Flow Chart
297
Measuring Vent Outlet Air Temperature
297
Air Leakage
298
Link and Wire Adjustment
299
Coolant By-Passing the Thermostat/Thermostat Stuck
299
Blower Unit Linkage Adjustment
299
Heater Unit Linkage Adjustment
299
Recommended Climate Control System Operation
300
Air Intake Selector
300
Function Selector
301
Temperature Selector Lever
301
Temperature Selector
302
Climate Control System Layout
302
Inoperative A/C - Blown Fusible Receiver/Dryer Plug
303
Poor A/C Cooling - Adjust A/C Thermostat
304
Nippondenso Air Conditioner
304
Removing Glove Box and under Cover
304
Repair Procedure
304
Removing 2 Screws Securing the Thermostat
305
Adjusting Thermostat
305
Poor Cooling - Diagnosing/Repair A/C Leaks
306
Diagnosis and Repair of A/C Refrigerant Leaks
306
Verify the Customer's Complaint
306
Verify the State of Charge Amount
306
Investigation and Repair
307
Leak Test
307
Freon Detector Inspection Angle
307
Damaged Component Illustration
307
Receiver Drier Replacement Criteria
308
Use of A/C Tracer Dye Service Info
312
When Using A/C Tracer Dye Method
312
Tracer Dye Suppliers
313
Refrigerant/Compressor Oil
313
Use of R-12 Refrigerant Substitutes
315
L4N71B Trans Oil Pressure Gauge Adapter
316
Oil Pressure Gauge Adaptor Installation
316
Painting Rustproof Steel Panels
317
Painting Rustproof Steel Panels Location Table
317
Location of Rustproof Steel Panels on 3 and 5-Dr Hatchbacks
319
Mazda 323 Wagon - Rustproof Body Panels
320
Mazda 626/MX-6 - Rustproof Body Panels
321
Mazda RX-7 - Rustproof Body Panels
322
Mazda 929 - Rustproof Body Panels
323
Mazda MPV - Rustproof Body Panels
324
Mazda "B" Series - Rustproof Body Panels
325
Static Electricity Shock When Exiting Vehicle
326
Recommended Anti-Static Products
326
Whistle Noise from Check and Cut Valves
327
Anything Installation
327
Wind Noise Around Doors
328
Card Test
328
Repair Procedure
328
White Grease Test
329
Door Adjustment
329
Grease Pattern - Measure
331
Hinge Mount - Outline
331
Windshield Stone Chipping Inspection
332
Inspection Procedure
332
Brake Caliper Bolt Corrosion
333
Brake Judder Repair
334
Causes of Judder
334
Correction
334
Service Tools
336
Warranty Information
336
Vibration/Pulsation While Braking
337
Brake Drums Labor Operation/Time Codes - 1993/95 Models
339
Rear Disc Brakes Labor Operation/Time Codes
341
Front Brakes Labor Operation/Time Codes - 1993/95 Models
344
1.2L Eng Cooling Fan Drive - New Grease for Cold
348
1983 RX-7 Cooling Fan Drive
348
Location of Bearing in Fan Drive
348
1.2L Hard Crank/No Start - Carbon in Rotor/Housing
349
Hard Cranking
349
View of Flywheel Turning Tool
349
Using Flywheel Turning Tool
350
Removing Inspection Plate from Convertor Housing
350
1.3L Eng Clutch VIB - Repl Flywheel Alignment Pins
352
Clutch Alignment Pins
352
83-86 RX7 Flywheel and Alignment Pins
352
Bad Shutter Valve Causes Rough Idle/No Idle
353
Rotary Rough Idle
353
Engine Stand Adaptor Modifications
354
Filling Cooling System
355
Caution When Adding Coolant
355
Caution When Replacing Coolant
355
View of Coolant Reservoir
355
Engine Coolant
355
Installing Mazda Brand Oil Filter
357
Installation Instructions Found on the Filter Boxes and the Filters
357
Engine Oil Filter Cartridge
357
All Models
357
Installation Procedure
357
Oil Leak at Rear Stationary Gear O-Ring - Car Fix
359
On-Car Replacement Procedure
359
Repair Procedure
359
Rear Stationary Gear, Oil Seal and Bolt - Insert Screwdrivers
360
Rear Stationary Gear, Oil Seal and Bolt - Remove and Clean
360
Parts Information
360
New Engine Replacement Program
362
B-Trucks New Engine Availability Parts Table
362
Partial Engine (Long Block) Availability
362
Propylene Glycol Based Coolant
367
Affected Models
367
Rattle from Floor When Accel - Broken Muffler Hanger
368
Pre-Silencer Hanger Breakage
368
View of Pre-Silencer with Stiffener
368
Reconditioned Anti-Freeze
369
Reconditioned Anti-Freeze Warnings
370
Revised Rotory Engine Pricing
371
1.2L Eng no Power/Stumble/Rough Idle/Bucking
373
1,2L New Throttle Sensor Adjusting Procedure
374
View of Test Connections in 1982 and 1983 Models
374
1.3L Eng Throttle Sensor Tool and Adjustment
375
Checking Throttle Sensor
375
RX7 Throttle Adjusting Tools
375
RX7 Throttle Sensor Checker Hookups
375
Adjusting Throttle Sensor
376
Throttle Sensor Testing
376
Throttle Sensor Checker Attachments
377
Throttle Sensor Adjusting Positions
377
California Reformulted Gasoline
378
Background
378
Mazda's Position on Carfg
378
Difference between Carfg and Other Gasolines
378
Carfg Affect on Vehicle Performance
379
Carfg Affect on Fuel Economy
379
No Special Additives Are Necessary When Using Carfg
379
Older Vehicle's Performance Using Carfg
379
Odor Emitted from Carfg
380
Additional Information Regarding Carfg
380
Choke System Maintenance Shedule/Cleaning Procedure
381
Spraying Cleaner on Carburetor
381
Article Beginning
381
Emission Inspection and Maintenance Test Preparations
382
Proper Preparation for State Emission Inspection and Maintenance Test
382
Preparation Procedure
382
Parts Bulletin - Spark Plug Coil/Wire
383
Recommended Fuel
386
Use of Regular Unleaded Gasoline
386
RX-7 Oil Replacement Tip
387
RX-7 Oil Filter Replacement
387
Spark Plugs for Piston Engines
388
Spark Plug Cross-Reference Chart
388
Spark Plug Identification for 1986-91 RX-7 Engines
390
TAS Location/Adjustment
391
Vehicle Affected
391
Throttle Adjustment Screw Locations
392
1.2/1.3 L Eng Clutch Chatter/Judder
394
Hard Shift to 2Nd Gear after Cold Start
396
2Nd Gear Synchronizer Ring and Assembly
396
Warranty Information
397
Improved Speedo Gear Sleeve to Eliminate Leaks
398
Speedometer Driven Gear Sleeve
398
VIN of Production
398
Speedometer Gear Sleeve and Gasket Modifications
398
M and R Type Trans Hard Shift Cold
400
Hard Shift in Low Temperature
400
Manual Trans New Bearing Cover Bolts/Torque
401
Modification of Bearing Cover Bolts
401
Bolt Information Table
401
VIN of Product Change
401
Manual Transmission Shim Adjustments
403
Manual Transmission Application Chart
404
Manshaft Rear Bearing
405
Retaining Ring Installation
405
Measuring Clearance between Thrust Washer and "C" Washer
405
R-Type
406
Installing Rear Bearing
406
Measuring Clearance between "C" Washer and Rear Bearing
406
Mainshaft Rear Bearing
407
Measuring Clearance between "C" Washers and Thrust Washer
407
Rear Bearing Installation
408
Measuring Clearance Between"C" Washer and Rear Bearing
408
Remanufactured Trans - Diagnosis Sheet
409
Rear Wheel Drive Pinion Height Adjustment
413
Location of Adjustment Numbers
413
Alignment Specifications
414
New Specifications Table
414
Vehicle Preparation and Condition
415
Caster Specification Table
415
Alignment Specifications and Tolerances
416
Caster Example Table
417
Aluminium Wheel Tire Change - Center Hub Damage Info
418
RX7, 626 and GLC Aluminum Wheel
418
Article Beginning
418
Checking Procedure for Power Steering Boot Leakage
419
Power Steering Gear and Boot Wire - Inspect Fluid Leakage
420
High Steering Wheel Effort - Verify Condition
421
Installation of Tire Chains
422
Revised Idler Arm/Dust Seal
423
Idler Arm Modification
423
Steering Wheel Slightly off Center
424
Tie Rod Circumference Distance Table
424
Catalyst Pellets and Modification of Secondary Air Sys
426
Mazda RX-7 Exhaust Emission System Recall Campaign
426
Defect Information Report
426
EPA Recall Surveillance Test Results
426
Voluntary Emission Recall Report
427
Recall Campaign Bulletin
428
Subject Vehicles
428
Notification
429
Campaign Parts
429
Recall Parts Kit
429
Related Parts
429
Parts Information
429
Exchange Units of Converter Housing
430
Air Control Valve Components
430
Installation of Secondary Air Orifice
431
Repair Procedures
431
Inspection and Adjustment of Choke Wire
432
Disconnecting Hose from Air Pump
432
Air Hose with Orifice Installed
432
Air Control Valve (ACV)
433
Measuring Clearance between Lock Nut and Bracket
433
Checking Choke Valve Opening
433
Hot Air Duct Location
434
Disconnecting Air Hose between Air Cleaner and ACV
434
Sliding Clamp on Air Hose
435
Proper Check Valve Orientation
435
Removing Cap and Switching Valve
436
Location of Hole for Enlargement
436
Blowing Chips off with Air Gun
437
Replacement of the Catalyst Pellets
438
Check Valve Position and Orientation
438
Location of Drain Plugs No. 1 and 2
439
Proper Positioning of Converter in a Vise
439
Converter in Level Position
440
Installing New Lock Washer on Converter
440
Replacement of the Catalytic Converter
441
Location of Drain Hole No. 2
441
Distribution of New and Old Pellets in Converter
441
Location of Protector No. 2
442
Removing Silencer Hangers
442
Bending Back Tip of Exhaust Pipe Lowe Cover
443
Removing Catalytic Converter
444
Tightening Flange Nuts
445
Location to Affix Recall Label
446
Tagging Returnable Pellets
446
Idler Arm Pin Breakage Could Cause Loss of Steering
449
NHTSA Recall Bulletin
449
Vehicle Description
449
Description of Deffect
449
Wiring Diagram Symbols
450
How to Use the Wiring Diagrams
450
Color Abbreviation Identification
451
Identifying Tie-Off Symbols
451
Identifying Option Symbols
451
Wiring Diagram Symbol Identification
452
Wiring Diagrams
455
Engine Compartment
455
Fuse Block and Underdash
456
Underdash and Instrument Panel
457
Rear Compartment and Accessories
458

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