Mazda 1979-1984 RX7 Technical Service Bulletin Download Page 28 | Manualshive

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HEATING SYSTEM TROUBLESHOOTING CAT. U, NO. 93-04

Article Text (p. 3)

1983 Mazda RX7

For www.iluvmyrx7.com

Copyright © 1998 Mitchell Repair Information Company, LLC

Monday, August 27, 2001 06:36AM

1. Collect detailed complaint information from the customer using
the Customer Comment Sheet.

2. Use the information collected on the Customer Comment Sheet to
determine the nature of the complaint.

3a. Refer to the diagnostic flow chart and determine the necessary
checks.

3b. After determining the complaint is of a usage nature instruct
the customer on the proper operation of the system.

4. Use the Check Sheet to perform the necessary repairs.

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

CUSTOMER COMMENT SHEET

Please complete the following with the aid of the customer.

1. Heater Concern

ÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

No.

³

Customer Comment

³

Checked

³

Result

ÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

1

³

Water temp indicator reads low at

³

³

³

high speed

³

³

ÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

2

³

While driving the interior temp.

³

³

³

is cooler than when parked

³

³

ÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

3

³

Heater outlet air temperature is

³

³

³

always cold

³

³

ÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

4

³

Passenger side is cooler than

³

³

³

driver's side

³

³

ÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

5

³

Passenger feels cold air at feet

³

³

ÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

6

³

After vehicle interior has

³

³

³

reached normal temperature cool

³

³

³

air is felt at body

³

³

ÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

7

³

Upper body is cooler than foot

³

³

ÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÅÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

8

³

Temperature is unbalanced between

³

³

³

driver's and passenger's side

³

³

ÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÁÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

2. Defroster Concern

ÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÂÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ

1

³

At cold temperatures or high

³

³

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Summary of Contents for 1979-1984 RX7

Page 1: ...7 com This file is fully text searchable select Edit and Find and type in what you re looking for This file is intended more for online viewing than printing out so some graphics may not print 100 leg...

Page 2: ...SUBJECT ENGINE Fuse Blows No Start REFERENCE Mazda Motors Corp Service Bulletin No 15 012 85 September 1985 CONDITION CAUSE Some 1979 84 RX7 vehicles may exhibit an ENGINE fuse that blows preventing t...

Page 3: ...RAW AMPERAGE All Vehicles 15 to 25 mA Ignition key is removed or in the lock position NOTE If the ignition key is in the ACC position up to 250 mA is drawn from the battery This current draw is large...

Page 4: ...T 5 NO 017 88 Article Text p 2 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 29AM damaged by the excessive current Fig 1 Testing...

Page 5: ...a unit through the exchange program However in case of a shortage of refurbished alternators you may replace the IC regulator to minimize inconvenience of customers see Fig 1 Fig 1 Exploded View of Al...

Page 6: ...ight 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 30AM Fig 2 Location of F Terminal REPAIR PROCEDURE Please refer to the Service Information for IC regulator replacing procedu...

Page 7: ...ccurate information of customer s complaint Carry out appropriate diagnosis or troubleshooting to find the faulty part Avoid replacing unnecessary parts Verify whether the customer s complaint results...

Page 8: ...OTING PROCEDURES CAT 15 NO 078 89 Article Text p 2 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 30AM Fig 1 Audio System Troubles...

Page 9: ...t it is possible for wire clip to become pinched in the threads on the clamp bolt resulting in the nut binding on the clamp rod See Fig 1 If you encounter this problem please follow the repair procedu...

Page 10: ...75 66 710A 1980 RX 7 Under Dash 8130 66 710 1980 RX 7 Engine Compartment 8341 18 055 1981 RX 7 Under Dash FA02 67 099 1981 85 RX 7 Engine Compartment 3777 67 099 1981 85 RX 7 Transmission 8341 18 055...

Page 11: ...icle Text p 2 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 31AM 1992 MX 3 Engine Compartment FB01 67 099 1984 86 GLC Wagon Engin...

Page 12: ...To stop the noise unplug the oscillator The oscillator is used as a dash instrument circuit backup Removing the oscillator has no other effect except to stop the constant buzzing noise Courtesy of Imp...

Page 13: ...Models GLC 626 RX 7 B2000 Bulletin No 010 85 Category 15 Date 6 25 85 DESCRIPTION The speed nut for fixing the key less switch to the ignition key cylinder housing has been established as a service pa...

Page 14: ...les may exhibit one or more of the following electrical problems RADIO ANTENNA fuse blown TAIL ILLUM fuse blown METER BACK fuse blown OPENER fuse blown Inoperative rear defroster rear wiper Rear wiper...

Page 15: ...DESCRIPTION The following procedure should be used to repair broken grid lines on rear window defrosters Place a copy of these procedures in the appropriate section of the workshop manual REPAIR PROCE...

Page 16: ...clean brush for future applications 9 Repeat application total of 3 times when the surface is tack free approximately one 1 minute 10 Allow to dry twenty 20 minutes 11 Carefully peel stencil from gla...

Page 17: ...18 85 DESCRIPTION A new wiper link has been established as a service part This new wiper link features a bushing as shown in Fig 1 Fig 1 1981 85 RX7 Wiper Link PARTS INFORMATION NEW PART NO OLD PART...

Page 18: ...ancel cam is available separately and can be replaced as shown below REPAIR PROCEDURE 1 Put a mark on the steering wheel and steering shaft so that the steering wheel can be reinstalled in the same po...

Page 19: ...r See Fig 3 6 Install the new cancel cam to the combination switch NOTE It is not necessary to apply additional grease to the cancel cam Fig 3 Removing Cancel Cam from Switch 7 Align the tabs of the c...

Page 20: ...EL REPLACE CANCEL CAM CAT 14 NO 010 85 Article Text p 3 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 34AM Fig 4 Aligning Cancel...

Page 21: ...nthreaded portion of studs for air conditioner compressor bracket has been extended for common use of the parts with other models Because of this change since the production date of September 1983 it...

Page 22: ...Mitchell Repair Information Company LLC Monday August 27 2001 06 35AM PARTS INFORMATION Plain washers are not included in the 1983 RX7 kits but will be in 1984 However these washers will be available...

Page 23: ...nectors If the indicator light on the air conditioner switch does not illuminate or illuminates dimly after installation the problem may be due to incorrectly assembled G 03 or G 16 connectors See Fig...

Page 24: ...HARNESS CONNECTOR CAT 16 NO 008 85 Article Text p 2 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 35AM Fig 2 RX7 A C Accessory C...

Page 25: ...ly charged Also please note that over charging the Air Conditioning system can cause higher than normal system pressures which could result in Air Conditioning System component damage The recommended...

Page 26: ...nfirmed SPECIAL NOTE This same manual will also be used as a hand out for all forth coming Training Courses on Climate Control Systems HEATER AND DEFROSTER TROUBLESHOOTING MANUAL INTRODUCTION An inves...

Page 27: ...System USING THIS MANUAL Follow the flow charts and diagnostic procedures below to repair the complaints which were determined on the Customer Comment Sheet 1 Complete customer comment sheet 2 Determ...

Page 28: ...truct the customer on the proper operation of the system 4 Use the Check Sheet to perform the necessary repairs CUSTOMER COMMENT SHEET Please complete the following with the aid of the customer 1 Heat...

Page 29: ...ield is only cleared 30 50 3 Rear window does not clear 4 Rear window clears only in the middle 3 Temperature Control Concern 1 Difficult to set temperature 2 Temperature unbalance between head and fo...

Page 30: ...formation Company LLC Monday August 27 2001 06 36AM Fig 2 Diagnostic Flow Chart CHECK SHEET Heater concern Item 1 Measuring Vent Outlet Air Temperature 1 Place transmission in park or place manual tra...

Page 31: ...temperature reading thermostat closed Item 2 Air Leakage A Interior Components 1 Remove the lower kick panel on passenger side 2 Remove the glove box 3 Adjust the climate controls to the following set...

Page 32: ...on the passenger side of the vehicle 2 Remove the glove box 3 Place the transmission in park or set manual transmission in neutral and set the parking brake 4 Start the engine and allow to idle 5 Set...

Page 33: ...er and set it on the work bench Closely watch as the thermostat begins to close and that it closes smoothly and does not hang up 6 If the thermostat fails either of the above tests Replace it 7 Using...

Page 34: ...ront or side windows begin to fog again while driving the selector should be reset to the defrost heat or full defrost and the fan speed adjusted as necessary In addition to the above air conditioning...

Page 35: ...ormation Company LLC Monday August 27 2001 06 36AM Fig 7 Temperature Selector Type A and B Climate Control System Shown in Fig 8 is a typical climate control system Detailed descriptions of each funct...

Page 36: ...g system This condition may be caused by a variety of factors blowing the fusible plug on the receiver drier REPAIR 1 If the fusible plug on the receiver drier is blown replace the receiver drier and...

Page 37: ...e air conditioner on RX 7 13B vehicles please follow the procedure described below REPAIR PROCEDURE 1 Check the air conditioning system for insufficient cooling according to the current Service Inform...

Page 38: ...7AM Fig 2 Removing 2 Screws Securing the Thermostat 4 Turn the adjusting screw of the thermostat clockwise 90 from the original position CAUTION Do not turn the adjusting screw more than 90 otherwise...

Page 39: ...ement VERIFY THE CUSTOMER S COMPLAINT 1 Check the outlet air volume and temperature However the outlet temperature will vary according to ambient conditions 35 45 degrees F is normal 2 Verify the comp...

Page 40: ...with O ring replacement and proper torquing but please pay attention to the failure on pipe and components Fig 3 Fig 3 Damaged Component Illustration LEAK TEST 1 After replacing O rings or components...

Page 41: ...ceiver drier when replacing other A C components Do not replace the receiver drier unless the following criteria have been met RECEIVER DRIER REPLACEMENT CRITERIA Replace the receiver drier when the A...

Page 42: ...wn Transparent or Yellowish Gray 2 Inspect Oil for Contamination Contamination Replace Present Part Receiver Drier icles of Metal or O Ring No Obvious Contamination Do Not Replace the Receiver Drier C...

Page 43: ...the receiver drier when replacing other A C components Do not replace the receiver drier unless the following criteria have been met RECEIVER DRIER REPLACEMENT CRITERIA Replace the receiver drier when...

Page 44: ...rown Transparent or Yellowish Gray 2 Inspect Oil for Contamination Contamination Replace Present Part Receiver Drier icles of Metal or O Ring No Obvious Contamination Do Not Replace the Receiver Drier...

Page 45: ...NOTE Different manufacturers have different methods for installing measuring and diagnosing with their particular product CAUTION Use only a tracer dye that is compatible with the type of refrigerant...

Page 46: ...ent Corporation Equivalent Ford See Dealer 112 R0027 Or Equivalent Rotunda REFRIGERANT COMPRESSOR OIL REFRIGERANT COMPRESSOR OIL INFORMATION TABLE Compressor Model Model Year Refrigerant Oil Type MX 6...

Page 47: ...7 com Copyright 1998 Mitchell Repair Information Company LLC Monday September 03 2001 03 26PM 1994 and after R134a ATMOS GU10 Navajo 1993 and prior R12 ESHM2C31A2 1994 and after R134a WSHM1C231B B Ser...

Page 48: ...Systems Bulletin No 009 96 Date October 21 1996 DESCRIPTION Mazda Corporation does not approve of using substitute R 12 refrigerants when an A C system requires charging Use of these products may res...

Page 49: ...X 7 A T Bulletin No 018 87 Date 4 9 87 Category 40 DESCRIPTION An adaptor for the 4903 78 400A oil pressure gauge has been newly established for 1983 87 RX7 with automatic transmission This adaptor is...

Page 50: ...paration of the surface finishing otherwise paint damage such as peeling off or blistering may result Please refer to the following instructions for proper repairs of the rustproof steel panels REPAIR...

Page 51: ...Monday August 27 2001 06 40AM Front Door Outer Panel Rear Door Outer Panel Side Sill Outer Panel Rear Fender Panel Fuel Filler Lid Rear Crossmember Rear End Member or Extension Tailgate Outer Panel T...

Page 52: ...PANELS CAT 14 NO 070 89 Article Text p 3 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 40AM Fig 1 Location of Rustproof Steel Pan...

Page 53: ...OF STEEL PANELS CAT 14 NO 070 89 Article Text p 4 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 40AM Fig 2 Mazda 323 Wagon Rustpr...

Page 54: ...OOF STEEL PANELS CAT 14 NO 070 89 Article Text p 5 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 40AM Fig 3 Mazda 626 MX 6 Rustpr...

Page 55: ...PROOF STEEL PANELS CAT 14 NO 070 89 Article Text p 6 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 40AM Fig 4 Mazda RX 7 Rustproo...

Page 56: ...PROOF STEEL PANELS CAT 14 NO 070 89 Article Text p 7 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 40AM Fig 5 Mazda 929 Rustproof...

Page 57: ...PROOF STEEL PANELS CAT 14 NO 070 89 Article Text p 8 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 40AM Fig 6 Mazda MPV Rustproof...

Page 58: ...L PANELS CAT 14 NO 070 89 Article Text p 9 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday August 27 2001 06 40AM Fig 7 Mazda B Series Rustproof Body...

Page 59: ...sionally feel static electricity shock when they touch the door after getting out of the vehicle If you encounter the customer complaint on the above condition spray anti static agent to the surface o...

Page 60: ...Whistle Noise From Check Cut Valve REFERENCE Mazda Motors Corp Service Bulletin No 4 015 85 September 1985 CONDITION CAUSE Some 1980 85 RX7 and 1981 85 GLC vehicles may exhibit a whistle noise from th...

Page 61: ...URE 1 Verify customer complaint 2 Examine weather strip for the following conditions a Rips tears cuts b Loose or falling off c Excessive deterioration If the weather strip has any of the above condit...

Page 62: ...rn that is left along the length of the weather strip check for any unevenness in width See Fig 2 a If 4 mm or more sealing contact is adequate if door closing effort is acceptable Clean grease from v...

Page 63: ...adjusted first followed by the striker Adjustment to the rear door s if applicable may require adjustments to the front door and possibly to the front fender to maintain alignment Door closing effort...

Page 64: ...T S NO 018 98 Article Text p 4 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Monday September 03 2001 03 34PM Fig 2 Grease Pattern Measure Fig 3 Hinge Mou...

Page 65: ...covered under the new vehicle warranty Service Advisers and Service Managers should review the criteria below for addressing customer complaints regarding cracked windshields If possible customers sho...

Page 66: ...einstalling disk brake calipers use the following procedure to secure the caliper bolts and seal against road corrosion When installing caliper mounting bolts first clean the bolt threads of any old r...

Page 67: ...ition CAUSES OF JUDDER 1 Disc Thickness Variation DTV DTV creates a vibration pulsation during application of the brakes DTV will increase with distance travelled if the run out of the disc is excessi...

Page 68: ...tud with chalk This will determine the original position of the wheel to the rotor Remove the front wheel s NOTE A high majority of brake judder is due to DTV of the front rotors Customer complaints o...

Page 69: ...6 25 Rear of Vehicle Rear Wheel Drive Only Operation Number P0113AMX 0 7 hrs Front One Side P0113BMX 1 2 hrs Front Both Sides P0214AMX 0 7 hrs Rear One Side P0214BMX 1 2 hrs Rear Both Sides NOTE 1 Unn...

Page 70: ...ns for each condition CAUSES OF JUDDER 1 Disc Thickness Variation DTV DTV creates a vibration pulsation during application of the brakes DTV will increase with mileage accumulation if the run out of t...

Page 71: ...ority of brake judder is due to DTV of the front rotors Customer complaints of brake judder are most often corrected by machining the front rotors only d Measure the remaining front rotor thickness an...

Page 72: ...r Wheel Drive Only Operation Number P0113AMX 0 7 hrs Front One Side P0113BMX 1 2 hrs Front Both Sides P0214AMX 0 7 hrs Rear One Side P0214BMX 1 2 hrs Rear Both Sides NOTE 1 Unnecessary replacement of...

Page 73: ...Operation P0201BRX 0 6 hrs 1993 94 Labor Operation P0201BRX 0 3 hrs 1995 Brake Drum s Machine one side Labor Operation P0201AMX 0 3 hrs Brake Drum s Machine both sides Labor Operation P0201AMX 0 6 hrs...

Page 74: ...ke Shoe s R R both sides Labor Operation P0204XRX 1 0 hrs 94 B Series and later Rear Brakes Brake Drums s R R one side Labor Operation P0201ARX 0 4 hrs Rear Brakes Brake Drums s R R both sides Labor O...

Page 75: ...le one sides Labor Operation P0214AMX 0 7 hrs Rear Brakes Disc Plate s Machine on vehicle both sides Labor Operation P0214BMX 1 2 hrs Rear Brakes Pad s R R one sides Labor Operation P0209ARX 0 3 hrs R...

Page 76: ...08ARX 0 4 hrs Rear Brakes Disc Plate s R R both sides Labor Operation P0208BRX 0 6 hrs Rear Brakes Disc Plate s Machine on vehicle one sides Labor Operation P0214AMX 0 7 hrs Rear Brakes Disc Plate s M...

Page 77: ...Labor Operation P0113AMX 0 7 hrs Front Brakes Disc Plate s Machine on vehicle both sides Labor Operation P0113BMX 1 2 hrs Front Brakes Pad s R R one sides Labor Operation P0104ARX 0 4 hrs Front Brakes...

Page 78: ...r Operation P0102ARX 0 3 1995 Front Brakes Disc Plate s R R both side Labor Operation P0208CRX 0 9 hrs 1993 94 Labor Operation P0208CRX 0 4 hrs 1995 Front Brakes Disc Plate s Machine on vehicle one si...

Page 79: ...or Operation P0113AMX 0 8 hrs 2WD Labor Operation P0113CMX 0 6 hrs 4WD Front Brakes Disc Plate s Machine on vehicle both sides Labor Operation P0113BMX 1 5 hrs 2WD Labor Operation P0113DMX 1 1 hrs 4WD...

Page 80: ...02CRX 1 1 hrs 2WD Labor Operation P0102DRX 1 6 hrs 4WD Front Brakes Disc Plate s Machine on vehicle one sides Labor Operation P0113AMX 0 8 hrs 2WD Labor Operation P0113CMX 0 6 hrs 4WD Front Brakes Dis...

Page 81: ...lletin No 019 83 Category 3 Date 2 1 83 DESCRIPTION In order to improve the characteristic of bearing grease in cold climates the type of grease has been changed Fig 1 Location of Bearing in Fan Drive...

Page 82: ...is started It will not occur when the engine is running To verify carbon trap the following two conditions must be confirmed l The problem occurred when the engine was started 2 The apex seal can be o...

Page 83: ...ates freely NOTE Do not use the starter to rotate the engine 7 Install the spark plugs 8 Check that the battery is fully charged 9 Start the engine and warm up to normal operating temperature 10 Stop...

Page 84: ...cle Text p 3 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 17AM CAUTION Do not turn the flywheel in the direction of normal...

Page 85: ...Symptom Clutch Vibration DESCRIPTION Replacement flywheels for the 1983 1986 RX 7 are shipped without clutch alignment pins These pins are necessary to accurately align the clutch cover to the flywhe...

Page 86: ...may be causing your idle problems is the vacuum hose that leads from the carburetor to the AA valve This large hose may be burned or split at the bend in the hose near the intake manifold and can int...

Page 87: ...3 88 Date 10 28 88 Category 40 DESCRIPTION With the introduction of universal engine hanger 49L0 10 1A0 a slight modification will be necessary on some types of engine stand adaptors If you currently...

Page 88: ...freezing protection ethylene glycol provides corrosion protection for aluminum engine parts Fig 1 View of Coolant Reservoir CAUTION WHEN ADDING COOLANT 1 If water only is added the mixture ratio of co...

Page 89: ...he radiator is full and the coolant level is at the FULL mark on the coolant reservoir NOTE If you encounter a reservoir bottle that is empty it is likely that the level of coolant inside the radiator...

Page 90: ...d 1 6 turns after the gasket contacts the filter base six dots are printed on the filter at even intervals to facilitate tightening instructions N3Y6 14 3020 Tighten by hand NOTE For rotary engine wit...

Page 91: ...e Surface of Gasket to the Surface of Gasket before Screwing on before Screwing on 2 Tighten 1 1 6 Turn after 2 Then tighten enough by Gasket Contacts Base hand 3 Start Engine and Check 3 Start Engine...

Page 92: ...he flywheel M T or counterweight A T Refer to the Workshop Manual section C and H 3 Set the front rotor to TDC top dead center per the Work shop Manual section C 4 Remove the six bolts from the RS gea...

Page 93: ...Mitchell Repair Information Company LLC Saturday September 08 2001 09 19AM 9 Install the RS gear Tightening torque 16 22 N m 10 Install remaining parts in the reverse order of removal 11 Verify repair...

Page 94: ...TION NOTE This information applies to verified customer complaints on vehicles covered under normal warranty Refer to the SRT microfiche for warranty term information The Operation Numbers Labor Hours...

Page 95: ...trical Parts 2 Cooling System Parts 3 Intake And Exhaust System Parts 4 Fuel And Emission Control Parts 5 Clutch And Or Flywheel WARRANTY INFORMATION Partial engines are warranted for the remainder or...

Page 96: ...rks 1989 94 MPV 2 6L G6Y5 02 300 8AL1 02 310 1989 94 MPV 4X2 JE57 02 300 8AL2 02 310 3 0L 4X4 JE58 02 300 8AL2 02 310 NAVAJO NEW ENGINE AVAILABILITY PARTS TABLE Year Model Engine P N Gasket P N Remark...

Page 97: ...P N Gasket P N Remarks 1981 82 626 HE41 02 300 8AU1 02 310 1983 85 626 FE01 02 300 8AG1 02 310 1986 87 626 FEY1 02 300 8AG2 02 310 Requires the replacement of NON TURBO the Heat Gauge Unit G607 18 510...

Page 98: ...ABLE Year Model Engine P N Gasket P N Remarks ALL RX 7 See Parts Bulletin R 6 MANA Rebuilt Rotary Engines MIATA NEW ENGINE AVAILABILITY PARTS TABLE Year Model Engine P N Gasket P N Remarks 1990 93 MIA...

Page 99: ...CK AVAILABILITY CAT B NO 004 94 Article Text p 5 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 19AM 2 5L V 6 KL47 02 300 8AK...

Page 100: ...CTED MODELS All Mazda Vehicles DESCRIPTION Mazda does not recommend propylene glycol coolants Available information indicates the following characteristics regarding propylene glycol coolants Provides...

Page 101: ...ory 4 Date 2 20 89 Symptom Noise DESCRIPTION If a rattling noise is heard from underneath the floor during the acceleration this may be due to the broken silencer hanger REPAIR PROCEDURE Check the exh...

Page 102: ...e coolants for all Mazda aluminum engines Although reconditioned anti freeze is available this product may contain silicon particles which may be abrasive to the water pump seal Additionally reconditi...

Page 103: ...RIPTION Mazda Motor Corporation MC does not recommend the use of reconditioned anti freeze Please use ethylene glycol base coolant for Mazda s aluminum engines Although it is available on the market r...

Page 104: ...es were effective 10 2 95 and are not reflected in List or the DMS tapes The DMS tapes will be updated the first week of November The next issue of the Dealer Price List will contain the new prices PA...

Page 105: ...OTORY ENGINE PRICING CAT RF NO 95 24 Article Text p 2 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 20AM W TWIN TURBO END OF...

Page 106: ...ollowing driveability problems Lack of acceleration hesitation on acceleration No power under load Engine stumble surge or bucking below approximately 3000 RPM Rough idle One or more of the above cond...

Page 107: ...D ADJUSTING PROCEDURES Models 1983 RX 7 Bulletin No 029 83 Category 1A Date 2 8 83 DESCRIPTION In order to ease extensive damage on emission control unit and related components electrical connection a...

Page 108: ...hment have been established for adjusting the throttle sensor for 1984 1985 REX 7 13B with E G I and 1981 1985 RX 7 12A with carburetor See Fig 1 Fig 1 RX7 Throttle Adjusting Tools PARTS INFORMATION P...

Page 109: ...turn counterclockwise If neither lamp illuminates turn the adjusting screw clockwise until only the red lamp illuminates Then turn the adjusting screw an additional 1 4 turn clockwise See Fig 3 5 Rei...

Page 110: ...rpm and release the throttle Check that the green and red lamps illuminate at the same time 6 If the green and red lamp do not illuminate at the same time proceed as follows Remove the cap from the ad...

Page 111: ...reformulated gasoline distributed in Southern California The California Air Resources Board CARB expects smog forming emissions from motor vehicles to decrease by approximately 15 due to CaRFG MAZDA...

Page 112: ...to the lower energy content of oxygenates which have been included in all Southern California gasoline since January 1995 and some gasoline since the 1970s NOTE Driving habits vehicle maintenance and...

Page 113: ...ted to smell different from gasoline most vehicles currently use If unusual odor is noticed it is probably be from oxygenates Most service stations use vapor recovery systems to minimize gasoline vapo...

Page 114: ...nt of choke valve choke system scheduled maintenance has been added as follows Federal Models every 15 000 miles California Models every 45 000 miles CHOKE SYSTEM CLEANING PROCEDURE 1 Use a cleaning a...

Page 115: ...ngine should be warmed up but not overheating as indicated by gauge or warning light All electrical loads and AC should be turned off For 5 speed models Neutral range should be selected For automatic...

Page 116: ...ndising purposes The carton can be placed on a wall display The part number and model applications are clearly indicated on the front and on the end of the carton Each wire is numbered for easy instal...

Page 117: ...1983 87 626 FWD RC ZX99A 0000 18 099A 1983 87 B2000 RC ZX99A 0000 18 099A 1986 91 RX 7 All Models RC ZE02 0000 18 100A 1987 93 B2600 RC ME51 0000 18 101A 1988 89 323 Turbo RC ZE07 0000 18 102A 1988 91...

Page 118: ...626 MX 6 2 5L RC ZE28 0000 18 128A 1995 626 2 5L RC ZE32 0000 18 132A 1993 94 626 MX 6 2 0L RC ZX29 0000 18 129A 1995 626 2 0L A T RC ZX40 0000 18 140A 1995 626 MX 6 2 0L M T RC ZX41 0000 18 141A 1993...

Page 119: ...d in all Mazda vehicles NOT equipped with a turbocharger All non turbocharged Mazda vehicles are designed to perform best when REGULAR UNLEADED fuel is used Due to the low volatility of some SUPER UNL...

Page 120: ...ain while the crankcase drains Now you can remove an empty filter rather than a full one due to the check valve inside the filter No more mess filters dripping all over the top of the engine Courtesy...

Page 121: ...MPV ZFR5F11 F287 18 110 1993 MX6 626 4CYL BKR5E11 BP01 18 110 STD TYPE 1993 MX6 626 4CYL BKR6E11 BP03 18 110 COLD TYPE 1993 MX6 626 V6 ZFR5F11 F287 18 110 STD TYPE 1993 MX6 626 V6 ZFR6E11 F285 18 110...

Page 122: ...10 Resistor Plug 1974 76 REPU B7EM 2328 18 600 8AH1 18 110A BP 1977 REPU B7ET 3743 18 600 8AF1 18 110A BP 1971 74 RX 2 B7EM 2328 18J600 8AH1 18 1 10A BP 1972 75 RX 3 B7EM 2328 18 600 8AH1 18 1 10A BP...

Page 123: ...ART NO T 1 3 Article Text p 3 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 31AM Fig 1 Spark Plug Identification for 1986 91...

Page 124: ...trol motors should NOT have the TAS Throttle Adjustment Screw adjusted for any reason The TAS functions as a stopper when the throttle valve is fully closed During production the TAS is accurately set...

Page 125: ...ATION ADJUSTMENT CAT F NO 014 98 Article Text p 2 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 32AM Fig 1 Throttle Adjustme...

Page 126: ...T Whistle Noise From Check Cut Valve REFERENCE Mazda Motors Corp Service Bulletin No 4 015 85 September 1985 CONDITION CAUSE Some 1980 85 RX7 and 1981 85 GLC vehicles may exhibit a whistle noise from...

Page 127: ...86 RX7 SUBJECT Clutch Chatter Judder REFERENCE Mazda Motors Corp Service Bulletin No 6 003 86 April 1986 CONDITION CAUSE Some 1983 86 RX7 vehicles may exhibit clutch chatter judder This condition may...

Page 128: ...Symptom Clutch Vibration DESCRIPTION Replacement flywheels for the 1983 1986 RX 7 are shipped without clutch alignment pins These pins are necessary to accurately align the clutch cover to the flywhe...

Page 129: ...ehicle has had sufficient time to warm up may be caused by insufficient clearance between 2nd gear synchronizer ring and the 1 2 clutch hub Design changes have been made to the 2nd gear synchronizer r...

Page 130: ...Number Description Qty Interchange ability New Old M502 17 265C M502 17 265B 2nd Synchronizer Ring 1 New Old M503 17 262A M503 17 262 1 2 Clutch Hub Sleeve 1 New Old M505 17 260B M505 17 260A 1 2 Clu...

Page 131: ...eeve the shape of the driven gear sleeve has been changed as shown In addition the shape of the gasket for the 323 has also been changed These modifications were made on the production line since Nove...

Page 132: ...ay September 08 2001 09 43AM Long Bed JM2UF211 H0603331 Cab Plus JM211311 PARTS INFORMATION NEW PART NO OLD PART NO DESCRIPTION APPLIED MODEL F401 17 442A F401 17 442 Speedometer Sleeve 323 323W 1669...

Page 133: ...us Oil Current Oil RX 7 SAE80W 90 SAE75W 90 929 SAE75W 80 SAE75W 90 B2200 SAE75W 80 SAE75W 90 B2600 SAE75W 80 SAE75W 90 VIN OF PRODUCTION CHANGE RX 7 JM1FC 10626727 July 9 1988 929 JM1HC K0200684 July...

Page 134: ...bolts attaching the transmission bearing cover have been strengthened and the tightening torque has been increased to improve the durability of the transmission BOLT INFORMATION TABLE Identification m...

Page 135: ...rx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 43AM RX 7 12A JM1FB331 E0819695 February 1984 13B JM1FB332 E0819695 February 1984 PARTS INFORMATION NEW PAR...

Page 136: ...es 1988 90 929 1999 90 MPV 1990 MX 5 Miata Date March 2 1990 No 001 90 Group J DESCRIPTION On vehicles 1981 90 RX7 and B Series 1988 90 929 1989 90 MPV 1990 MXS with rear wheel drive and manual transm...

Page 137: ...Repair Information Company LLC Saturday September 08 2001 09 44AM Fig 1 Manual Transmission Application Chart 1 Install the synchronizer ring and 5th gear 2 Insert the steel ball and thrust washer 3 I...

Page 138: ...ect 4 While pushing the C washers forward measure the clearance between the thrust washer and C washers See Fig 3 Fig 3 Measuring Clearance Between Thrust Washer C Washer M Types If the clearance is n...

Page 139: ...ition are the same thickness 3 Measure the clearance between the C washers and mainshaft rear bearing See Fig 5 If the clearance is not as specified select the proper C washers Fig 5 Measuring Clearan...

Page 140: ...the measurement will be incorrect 4 While pushing the C washers forward measure the clearance between the C washers and thrust waster See Fig 7 Fig 7 Measuring Clearance Between C Washers Thrust Washe...

Page 141: ...not fit into the rear mainshaft groove select the proper thickness C washers Ensure both C washers at this position are the same thickness 3 Measure the clearance between the C washers and mainshaft r...

Page 142: ...Inc This division of Mazda supplies remanufactured units for both Canada and United States In their continued efforts to upgrade the quality of these remanufactured units they are looking for more inf...

Page 143: ...NO 95 02 Article Text p 2 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 44AM Fig 1 Example of Warranty Tag 3 The defective u...

Page 144: ...ive copies of the Automatic Transmission Diagnosis Information Sheet are being supplied with this bulletin Ensure 1 copy remains intact with the original bulletin so that additional copies can be prod...

Page 145: ...rmal Fluid Level ____ Correct ____ High ____ Low Line Pressure record applicable data Idle WOT P ____ N A R ____ ____ N ____ N A OD ____ ____ D ____ ____ 2 ____ ____ 1 ____ ____ 4 Replacement Transmis...

Page 146: ...d be used to obtain the adjustment value There are two types of markings 1 Handwritten marking with electric pen This number should be used for the adjustment value See Fig 1 Fig 1 Location of Adjustm...

Page 147: ...e condition of the vehicle at the time of measurement To avoid unnecessary adjustments specifications and measurement conditions have been changed in the Workshop Manual These changes are described be...

Page 148: ...ated Areas Tire Pressure Checked And If Necessary Adjusted NOTE If the specifications are different depending on load conditions adjust the pressure for the lightest load 2 The table below contains ex...

Page 149: ...d measuring conditions for wheel alignment Measured values are not absolute Variations occur between technician equipment and the condition of the vehicle at the time of measurement To avoid unnecessa...

Page 150: ...Engine Oil To The Specified Levels Spare Tire Jack And Tool Stored In Designated Areas Tire Pressure Checked And If Necessary Adjusted NOTE If the specifications are different depending on load condi...

Page 151: ...ls RX 7 626 GLC Bulletin No 002 85 Category 12 Date 6 17 85 DESCRIPTION If standard tire changers are used to change tires on aluminum wheels damage will occur to the center hub See Fig 1 The manufact...

Page 152: ...ection N of the workshop manual INSPECTION PROCEDURE 1 Check the color of the fluid that is leaking See Fig 1 If the fluid is red proceed to step 3 If the fluid is any color other than red i e yellow...

Page 153: ...7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 51AM gear CAUTION DO NOT keep the steering wheel fully turned to the locked position for more than five secon...

Page 154: ...y the amount of force required to turn the steering wheel Use the instructions in the Workshop Manual category N under Steering Wheel Effort This procedure involves using a pull scale CAUTION Before m...

Page 155: ...cles owner s manual 1 Investigate local regulations before using tire chains 2 Use only SAE Class S chains and make sure they fit the vehicle s tires 3 Follow the chain manufacturer s instructions 4 R...

Page 156: ...TION To increase the sealing efficiency of the dust seal the configurations of the dust seal and idler arm have been changed as shown since the production in March 1983 Fig 1 Idler Arm Modification VI...

Page 157: ...ing wheel is not centered go to step 2 2 Using the outside circumference of the steering wheel measure the distance between the neutral position and the center position NOTE If the distance is larger...

Page 158: ...l 7 mm 1992 95 626 MX 6 All 9 mm 1992 95 929 All 11 mm 4 x 2 13 mm 1989 95 MPV 4 x 4 12 mm 1990 95 MX 5 Miata All 10 mm 1995 Millenia All 10 mm WARRANTY INFORMATION Applies To Verified Customer Compla...

Page 159: ...emature deterioration of the vehicle s catalyst 3 Class or Category of Vehicles Potentially Affected 1982 83 Mazda RX 7 Federally Certified Vehicle 4 1 Number of Vehicles Estimated to Have the Defect...

Page 160: ...EMISSION RECALL REPORT 1 Description of Each Class of Subject Vehicles AFFECTED VEHICLES No for Make Year Model Serial Vehicle Number Range Recall Mazda 1982 RX 7 JM1FB3310C0600001 JM1FB3310D0764091 9...

Page 161: ...st 30 of the parts required for this campaign to dealers as an initial stock before the start of the recall campaign Thereafter a local distributor will supply necessary parts to dealers in accordance...

Page 162: ...5480 2 Nut 8118 40 3550 4 Bolt 9979 60 6100 2 Bolt 9979 60 8160 2 Spring Washer 9997 11 2000 4 Gasket ACV N201 13 7240 1 Secondary Air Orifice N201 13 5010 1 Recall Label N2Y1 20 6090 1 No 1 No 2 Pel...

Page 163: ...g 1 Fig 1 Air Control Valve Components 3 Exchange Units of Converter Housing We will provide 3 empty catalytic converter housings to each dealer as initial units of exchange operation Refer to the Not...

Page 164: ...nt of the pelleted converter housing ALL of the pellets are replaced In the rear compartment of the pelleted converter housing a specified amount of new pellets are installed and the remaining space i...

Page 165: ...m Air Pump 2 Insert the secondary air orifice included in the kit about 1 inch into the air pump side of the hose See Fig 3 Fig 3 Air Hose with Orifice Installed 3 Reconnect the hose II Inspection and...

Page 166: ...04 0 08 in Fig 4 Measuring Clearance Between Lock Nut and Bracket 5 If it is not within the specification adjust it by turning the lock nut 6 Install the lock spring 7 Remove the air cleaner cover 8...

Page 167: ...tion Company LLC Saturday September 08 2001 09 59AM 1 Remove the hot air duct See Fig 6 Fig 6 Hot Air Duct Location 2 Disconnect the air hose between the air cleaner and the air control valve See Fig...

Page 168: ...01 09 59AM Fig 8 Sliding Clamp on Air Hose Air Control Valve Side 4 Remove the air control valve and the air hose 5 Remove the check valve from air control valve CAUTION The check valve may fall out w...

Page 169: ...rx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 59AM Fig 10 Removing Cap and Switching Valve 7 Enlarge the hole as shown in Fig 11 with the 4 2 mm drill bi...

Page 170: ...eptember 08 2001 09 59AM Fig 12 Blowing Chips off with Air Gun 9 Re install the cap and switching valve removed in Step 6 10 Re install the check valve to the intake manifold CAUTION Be sure to fit th...

Page 171: ...ot air duct Be sure to install the clamps securely IV Replacement of the Catalyst Pellets A Preparation of Exchange Container As mentioned in Item E of attachment I the exchange container is to be par...

Page 172: ...a vise at an angle of 25 30 as shown in Fig 15 Fig 15 Proper Positioning of Converter in a Vise 3 Put the funnel provided in the drain hole No 1 front side 4 Pour all the pellets from the plastic bag...

Page 173: ...r repeatedly at points A and B until all pellets are in 8 Install a new lock washer and tighten the drain plug No 1 to the specified torque Torque to 30 50 N m Bend the lock washer to prevent the plug...

Page 174: ...in the rear of converter must later be filled with old pellets see Fig 19 from the converter removed from the customer s vehicle as described in Section IV B Step 8 through 11 below Fig 19 Distributi...

Page 175: ...ening because it may result in breakage of the bolt or stud Lubricate the threads with penetrating oil before loosening the bolts and nuts to prevent them from breaking 1 Lift the vehicle on a hoist 2...

Page 176: ...CAUTION Be careful not to cut your fingers on the edge of the lower cover Fig 22 Bending Back Tip of Exhaust Pipe Lowe Cover 6 Loosen the four nuts connecting the catalytic converter to the exhaust pi...

Page 177: ...ets from the rear of converter by shaking the converter over a clean pan that will catch the pellets 10 Pour the pellets removed at Step 9 into the rear compartment drain hole No 2 of the previously p...

Page 178: ...new nuts NOTE Be sure to install the converter correctly The drain plugs must be on the upper side 13 Tighten the flange nuts to specified torque See Fig 25 Specified Torque 55 80 N m 41 59 ft lb Fig...

Page 179: ...the charcoal canister in accordance with the repair procedure in the letter of Recall Campaign Number 21605 1982 RX 7 Evaporative Emission System Fig 26 Location to Affix Recall Label 19 Remove the dr...

Page 180: ...l vehicles Mazda is recalling them for free replacement of the catalyst pellets and modification of the secondary air system Neither of these operations will affect your vehicle s fuel economy or perf...

Page 181: ...PELLETS MODIFICATION OF SECONDARY AIR SYS Article Text p 23 1983 Mazda RX7 For www iluvmyrx7 com Copyright 1998 Mitchell Repair Information Company LLC Saturday September 08 2001 09 59AM Mazda END OF...

Page 182: ...ng FAULT Locks up Sticks Grabs DESCRIPTION OF DEFECT In certain high salt areas the idler arm is exposed to road salt which causes the dust seal to deteriorate resulting in idler arm pin corrosion Thi...

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