Mazda 2006-2008 RX7 Engine Workshop Manual Download Page 2

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Summary of Contents for 2006-2008 RX7 Engine

Page 1: ...of printing As modifications affecting repair or maintenance occur relevant information supplementary to this volume will be made available at Mazda dealers This manual should be kept up to date Mazda...

Page 2: ......

Page 3: ...Rounding Off 00 00 5 Upper and Lower Limits 00 00 5 FUNDAMENTAL PROCEDURES 00 00 6 Preparation of Tools and Measuring Equipment 00 00 6 Special Service Tools 00 00 6 Disassembly 00 00 6 Inspection Du...

Page 4: ...cleaning of parts and visual inspection have been omitted Service Procedure Inspection adjustment Inspection and adjustment procedures are divided into steps Important points regarding the location a...

Page 5: ...R TRAILING LINK UPPER TRAILING LINK REMOVAL INSTALLATION 1 Jack up the rear of the vehicle and support it with safety stands 2 Remove the undercover See 01 10 4 Undercover Removal 3 Remove in the orde...

Page 6: ...es added information that will help you to complete a particular procedure Specification The values indicate the allowable range when performing inspections or adjustments Upper and lower limits The v...

Page 7: ...0 kPa 2 1 2 7 kgf cm2 30 38 psi 270 310 kPa 2 7 3 2 kgf cm2 39 45 psi The actual converted values for 2 7 kgf cm2 are 264 kPa and 38 4 psi In the first specification 2 7 is used as an upper limit so t...

Page 8: ...e required Disassembly If the disassembly procedure is complex requiring many parts to be disassembled all parts should be marked in a place that will not affect their performance or external appearan...

Page 9: ...rd values such as torques and certain adjustments must be strictly observed in the reassembly of all parts If removed the following parts should be replaced with new ones Oil seals Gaskets O rings Loc...

Page 10: ...ecalculated due to the extra length that the SST or equivalent adds to the torque wrench Recalculate the torque by using the following formulas Choose the formula that applies to you A The length of t...

Page 11: ...nectors When disconnecting connector grasp the connectors not the wires Connectors can be disconnected by pressing or pulling the lock lever as shown Locking connector When locking connectors listen f...

Page 12: ...from the wiring harness side Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side Caution To prevent damage to the terminal...

Page 13: ...orless Ignition Direct Ignition EI Electronic Ignition Electronic Spark Ignition 2 ECT Engine Coolant Temperature Water Thermo EM Engine Modification Engine Modification Engine Speed Input Signal Engi...

Page 14: ...Injection Shift Solenoid A 12 Shift Solenoid Valve Shift A Solenoid Valve Shift Solenoid B 23 Shift Solenoid Valve Shift B Solenoid Valve Shift Solenoid C 34 Shift Solenoid Valve 3GR Third Gear 3rd G...

Page 15: ...CAMSHAFT INSPECTION 01 10 15 TAPPET INSPECTION 01 10 17 CYLINDER BLOCK INSPECTION 01 10 17 OIL JET VALVE INSPECTION 01 10 18 PISTON INSPECTION 01 10 18 CRANKSHAFT INSPECTION 01 10 19 CONNECTING ROD I...

Page 16: ...y Lock Bolt Assembly Note 01 10 41 Cylinder Head Cover Assembly Note 01 10 42 End of Toc ENGINE OVERHAUL SERVICE WARNING E5U011002000E01 Warning Continuous exposure with USED engine oil has caused ski...

Page 17: ...jury Never keep the engine in an unbalanced position and always hold the rotating handle firmly when turning the engine 6 Mount the engine on the SST engine stand 7 Drain the engine oil into a contain...

Page 18: ...ankshaft Pulley Lock Bolt Disassembly Note 5 Crankshaft pulley 6 Water pump pulley 7 Drive belt idler pulley Without stretch type A C drive belt 8 Engine front cover 9 Front oil seal See 01 10 5 Front...

Page 19: ...sing a screwdriver Chain Tensioner Disassembly Note 1 Unlock the chain tensioner ratchet using a suitable screw driver or equivalent tool 2 Slowly press the tensioner piston 3 Hold the chain tensioner...

Page 20: ...bolt variable valve timing actuator lock bolt With variable valve timing mechanism See 01 10 7 Camshaft Sprocket Lock Bolt Variable Valve Timing Actuator Lock Bolt Disassembly Note 2 Camshaft sprocke...

Page 21: ...the following Camshaft end play and camshaft journal oil clearance See 01 10 15 CAMSHAFT INSPECTION Note The camshaft caps are numbered to make sure they are assembled in their original positions Whe...

Page 22: ...rder indicated in the table Valve Keeper Disassembly Note 1 Remove the valve keeper using the SSTs 9 8 7 4 3 1 2 10 5 6 B3E0110E059 8 7 5 4 3 1 1 2 6 SST SST R R B3E0110E060 1 Engine hanger 2 Valve ke...

Page 23: ...1 R R R R R R SST SPIN ON TYPE CARTRIDGE TYPE WITH OIL COOLER MTX R 9 8 7 1 5 4 3 2 13 12 OIL OIL R R IF EQUIPPED 10 11 R WITHOUT OIL COOLER 6 6 E5U110ZE7S10 1 Flywheel MTX Drive plate ATX See 01 10 1...

Page 24: ...49 E011 1A0 B3E0110E051 9 8 7 5 4 3 1 2 10 6 11 12 L3 L3 10 E5U110ZE7S07 1 Balancer unit 2 Adjustment shim 3 Connecting rod cap See 01 10 11 Connecting Rod Cap Disassembly Note 4 Lower connecting rod...

Page 25: ...e figure End Of Sie CYLINDER HEAD INSPECTION E5U011010100E01 1 Perform color contrast penetrate examination on the cylinder head surface Replace the cylinder head if necessary 2 Inspect for the follow...

Page 26: ...04 25 mm 4 104 in 3 Measure the stem diameter of each valve in X and Y directions at the three points A B and C as indicated in the figure If it exceeds the specification replace the valve Valve stem...

Page 27: ...ht dimension A of each valve guide without lower valve spring seat If not within the specified replace the valve guide Valve guide protrusion height standard 12 2 12 8 mm 0 481 0 503 in End Of Sie VAL...

Page 28: ...in 2 Verify that the valve seating position is at the center of the valve face 1 If the seating position is too out side correct the valve seat using a 70 IN or 65 EX cutter and a 45 cutter 2 If the...

Page 29: ...square Maximum 1 95 mm 0 0767 in End Of Sie CAMSHAFT INSPECTION E5U011012420E01 1 Set the No 1 and No 5 journals on V blocks 2 Measure the camshaft runout If it exceeds the specification replace the...

Page 30: ...haft cap See 01 10 7 Camshaft Cap Disassembly Note 9 Measure the oil clearance If it exceeds the specification replace the cylinder head Camshaft journal oil clearance Standard 0 035 0 080 mm 0 0014 0...

Page 31: ...clearance Standard 0 02 0 06 mm 0 0008 0 0023 in Tappet to Tappet bore oil clearance Maximum 0 15 mm 0 006 in End Of Sie CYLINDER BLOCK INSPECTION E5U011010300E01 1 Measure the distortion of the cyli...

Page 32: ...in piston ring and connecting rod as a single unit Piston diameter Standard 87 465 87 495 mm 3 4435 3 4446 in 2 Measure the piston to cylinder clearance If not within the specification replace the pis...

Page 33: ...0 45 mm 0 0087 0 0177 in Crankshaft end play Maximum 0 55 mm 0 0216 in 3 Remove the main bearing cap See 01 10 11 Main Bearing Cap Disassembly Note 4 Measure the crankshaft runout If it exceeds the sp...

Page 34: ...nstall the connecting rod cap See 01 10 29 Connecting Rod Cap Assembly Note 2 Measure the connecting rod large end side clearance If it exceeds the specification replace the piston piston pin piston r...

Page 35: ...e it is a precision unit 1 Confirm that the groove of the rotor and notch of the cover at the variable valve timing actuator are aligned and fixed If the notch and the bump are not aligned rotate the...

Page 36: ...lve timing retard position If it exceed the specification replace the oil control valve OCV End Of Sie VALVE CLEARANCE INSPECTION E5U011012111E03 1 Measure the valve clearance as follows 1 Turn the cr...

Page 37: ...maged 5 Turn the crankshaft clockwise so that the crankshaft is in the No 1 cylinder TDC position 6 Loosen the timing chain 1 Using a suitable screwdriver or equivalent tool unlock the chain tensioner...

Page 38: ...t 12 Select proper adjustment shim New adjustment shim Removed shim thickness Measured valve clearance Standard valve clearance IN 0 25 mm 0 0098 in EX 0 30 mm 0 0118 in Valve clearance Engine cold IN...

Page 39: ...ain 19 Turn the crankshaft clockwise so that the crankshaft is in the No 1 cylinder TDC position 20 Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure 21 Tigh...

Page 40: ...117 kgf cm 71 101 in lbf 26 Install the cylinder block lower blind plug Tightening torque 18 22 N m 1 9 2 2 kgf m 13 3 16 2 ft lbf 27 Install the new engine front cover lower blind plug Tightening to...

Page 41: ...3 3 16 2 87 5 92 5 PLASTIC REGION TIGHTENING BOLT BOLT STEM LENGTH 110 mm 44 46 4 5 4 6 32 5 33 9 175 185 SST SST SST E5U110ZE7S03 1 Oil jet valve 2 Upper main bearing thrust bearing 3 Crankshaft 4 Lo...

Page 42: ...7 19 9 ft lbt 4 38 42 N m 3 9 4 2 kgf m 28 1 30 9 ft lbt 5 Loosen all the bolts no remaining torque 6 3 7 N m 30 6 71 3 kgf cm 26 6 61 9 in lbt 7 18 22 N m 1 9 2 2 kgf m 13 3 16 2 ft lbt 8 87 5 92 5 P...

Page 43: ...ng torque 1 26 32 N m 2 7 3 2 kgf m 19 2 23 6 ft lbf 2 80 100 Balancer Unit Assembly Note 1 Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft tur...

Page 44: ...him selection table select the proper shim according to the following procedure Caution When measuring the backlash rotate the crankshaft one full rotation and verify that it is within the specified r...

Page 45: ...0330 42 1 42 0 0559 0 211 0 217 0 00830 0 00854 23 1 23 0 0484 0 071 0 077 0 00279 0 00303 43 1 43 0 0562 0 204 0 210 0 00803 0 00826 24 1 24 0 0488 0 064 0 070 0 00251 0 00275 44 1 44 0 0566 0 197 0...

Page 46: ...N m 81 6 122 3 kgf cm 70 9 106 2in lbf 20 25 8 0 11 5 N m 81 6 117 2 kgf cm 70 9 101 7 in lbf SPIN ON TYPE CARTRIDGE TYPE WITH OIL COOLER MTX R R R IF EQUIPPED R OIL OIL SST WITHOUT OIL COOLER 17 23 1...

Page 47: ...htening torque 8 0 11 5 N m 81 6 117 2 kgf cm 70 9 101 7 in lbf Drive Plate ATX Flywheel MTX Assembly Note 1 Hold the crankshaft using the SST 2 Tighten the bolts in the 3 steps in the figure Tighteni...

Page 48: ...e seal side of oil pan 2 Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side 3 Tighten the rear oil pan bolts in the order as shown in the figur...

Page 49: ...1 Install the valve keeper using the SSTs End Of Sie 8 8 7 5 4 3 1 2 6 SST SST R R 42 48 4 3 4 8 31 0 35 4 42 48 4 3 4 8 31 0 35 4 56 60 5 8 6 1 41 3 44 2 8 0 11 5 N m 81 6 117 2 kgf cm 70 9 101 7 in...

Page 50: ...0 11 5 N m 81 5 117 kgf cm 70 8 101in lbf 5 0 9 0 N m 51 0 91 7 kgf cm 44 3 79 5 in lbf 14 17 1 43 1 73 10 4 12 5 R R R WITH VARIABLE VALVE TIMING MECHANISM IF WASHER IS NOT INSTALLED TO THE ENGINE IN...

Page 51: ...tighten the camshaft bearing caps evenly in 2 3 steps 3 Tighten the camshaft cap bolt in the order shown two steps Tightening torque 1 5 0 9 0 N m 51 0 91 7 kgf cm 44 3 79 5 in lbf 2 14 17 N m 1 43 1...

Page 52: ...Oil pump chain 3 Oil pump sprocket See 01 10 39 Oil Pump Sprocket Assembly Note 4 Oil pump chain guide 5 Oil pump chain tensioner 6 Seal With variable valve timing mechanism 7 Timing chain See 01 10...

Page 53: ...mshaft position with the TDC 2 Remove the cylinder block lower blind plug 3 Install the SST as shown in the figure 4 Turn the crankshaft clockwise so that the crankshaft is in the No 1 cylinder TDC po...

Page 54: ...en the camshaft sprocket lock bolt Tightening torque 69 75 N m 7 1 7 6 kgf m 50 9 55 3 ft lbf Front Oil Seal Assembly Note 1 Apply clean engine oil to the oil seal 2 Push the oil seal slightly in by h...

Page 55: ...hat there is no oil or dust on the seal side of oil pan Thickness A 2 2 3 2 mm 0 087 0 125 in B 1 5 2 5 mm 0 059 0 098 in 2 Install the cylinder head cover bolts in the order as shown in the figure Cr...

Page 56: ...il the TDC position If not aligned loosen the crankshaft pulley lock bolt and repeat from Step 1 10 Install the cylinder block lower blind plug Tightening torque 18 22 N m 1 9 2 2 kgf m 13 3 16 2 ft l...

Page 57: ...rd IN 40 64 42 24 mm 1 600 1 662 in EX 40 50 42 10 mm 1 595 1 657 in Valve spring pressing force 390 N 39 76 kgf 87 67 lbf Valve spring standard height H 28 68 mm 1 129 in Valve spring out of square M...

Page 58: ...398 1 8405 in Crank pin journal diameter L3 STD 49 980 50 000 mm 1 9677 1 9685 in US0 25 49 730 49 750 mm 1 9579 1 9586 in Crank pin out of round Maximum 0 05 mm 0 0019 in Main journal oil clearance S...

Page 59: ...303 465 Camshaft Alignment timing Tool 1 49 G032 354 2 Adjusting wrench 1 49 B012 015 2 Valve guide installer 1 49 0636 100B 2 Valve spring lifter arm 1 49 B012 0A2 2 Pivot 1 49 L010 1A0 2 Engine han...

Page 60: ...SERVICE TOOLS 01 60 2 End Of Sie 1 49 G011 201 2 Attachment...

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