Mazda RX-7 1989 Service Highlights Download Page 4

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Summary of Contents for RX-7 1989

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Page 2: ...TROL 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 ...

Page 3: ...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 ...

Page 4: ...ges 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 _ ...

Page 5: ... TING RELATED TA PARTS BALANCE WEIGHT ECCENTRIC PULLEY REAR ROTOR FRONT ROTOR DRIVE PLATE COUNTER WEIGHT FLYWHEEL C 3 ...

Page 6: ...on 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 ...

Page 7: ...tnc 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 S de seal orner seal 1 ey lock bolt heel MIT lI 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 We...

Page 8: ...g 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 prote...

Page 9: ... COVER FRONT COVER GASKET FRONT COVER BACKUPRING 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 ...

Page 10: ...r 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 ...

Page 11: ...EM 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 ...

Page 12: ...ve 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 ...

Page 13: ... 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...

Page 14: ... 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...

Page 15: ...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 o...

Page 16: ...7 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 ...

Page 17: ...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 ...

Page 18: ...formance 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 THE...

Page 19: ...TY C F i I oc oF i mm 1n I kPa kg cm2 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 ...

Page 20: ...le 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 _ ...

Page 21: ...ty Jump gasket The shape is changed because of the bearing housing change earing and pulley boss The shaft bearing shaft outer diameter and pulley boss inner diameter are increased to incorporate the new cooling fan Jump body The body shape is changed to incorporate the new thermostat and cov er The water thermoswitch for automatic transmission and Turbo models is in the pump body al parts are int...

Page 22: ...et is used for improved serviceability The open1ng temperature is the same as the prev1ous model The outer diameter is decreased from 54mm 2 13 1n to 52mm 2 05 in for use w1th the rubber gasket Assemble the rubber gasket with the notch positioned around the Jiggle valve E 6 ...

Page 23: ... 415mm 16 34 in x thickness J 98 in because of the cooling fan improvements The radiator has a filler cap body for improved J l1ty By moving the radiator cap from the middle of the radiator to the filler cap body the need bleeder plug and the filler cap at the thermostat cover is eliminated Coolant replacement is done j E 7 ...

Page 24: ...F1 11 VARIABLE DYNAMIC EFFECT INTAKE VDI SYSTEM F1 12 FUEL SYSTEM F1 13 MIXING PLATE F1 13 SERVICE POINT F1 14 CONTROL SYSTEM F1 15 AIRFLOW METER F1 15 THROTTLE IDLE POSITION AUTO ADJUSTING SYSTEM F1 16 LEAN BEST IDLE CONTROL SYSTEM F1 17 SPARK ADVANCE FEEDBACK SYSTEM F1 18 SERVICE POINT F1 19 SELF DIAGNOSIS FUNCTION F1 20 DESCRIPTION F1 20 MALFUNCTION CODE NUMBER F1 21 SWITCH MONITOR FUNCTION F1 ...

Page 25: ...t Development concepts Improved parts Airflow meter L1near type M1x1ng plate Pnmary fuel 1nJ8ct1on Vanable dynam1c effect 1ntake VOl system Throttle 1dle pos1t1on auto adJUSting system Lean best 1dle control system Vanable res1stor el1m1nated Spark advance feedback system Related X Non related Increased horsepower X X X X Improved performance X X X I I Improved fuel economy X X X X Improved servic...

Page 26: ...TEM IMPROVED SERVICEABILITY I AIRFLOW METER IMPROVED PERFORMANCE MIXING PLATE CREASED HORSEPOWER L____ PROVED PERFORMANCE PROVED FUEL ECONOMY SPARK ADVANCE FEEDBACK SYSTEM IMPROVED PERFORMANCE F1 3 LEAN BEST IDLE CONTROL SYSTEM MPROVED FUEL ECONOMY MPROVED SERVICEABILITY 97UOF1 503 ...

Page 27: ...SPHERIC PRESSURE l SENSOR i y l o 1 J t l v WATER THERMOSENSOR PRESSURE SENSOR J r AIRFLOW METER INCLUDES INTAKE AIR THERMOSENSOR CRANK ANGLE SENSOR J I I F1 4 HEAT HAZARD SENSOR INHIBITOR SWITCH A T IGNITION SWITCH NEUTRAL SWITCH M T L BACK U P LIGHT AND 5TH SWITCH MIT MILEAGE SENSOR CIRCUIT OPENING RELAY OIL PRESSURE SWITCH A T MAIN RELAY 97UOF1 504 ...

Page 28: ...ROL VALVE INJECTOR PRIMARY SOLENOID VALVE ACCELERATED WARM UP SYSTEM PURGE CONTROL VALVE I A IGNITIONCOIL L I WITH IGNITER TRAILING SOLENOID VALVE RELIEF SOLENOID VALVE SWITCH AIR PUMP CHECK CONNECTOR SELF DIAGNOSIS CHECKER GREEN 6 PIN A C RELAY BLE DYNAMIC EFFECT INTAKE n INDUCTION SOLENOID VALVE PRESSURE REGULATOR CONTROL TEST CONNECTOR GREEN 1 PIN IGNITION COIL WITH IGNITER LEADING F1 5 ...

Page 29: ... PRESSURE REGULATOR TO CHARCOAL CANISTER PRESSURE REGULATOR WITH DELIVERY PIPE CHARCOAL I CANISTER CHECK CONNECTOR FUEL PUMP YELLOW 2 PIN nc n PULSATION DAMPER F f 1 1 WITH DELIVERY PIPE FUEL PUMP RESISTOR RELAY G Q _ F1 6 INJECTORS I 97UOF 506 ...

Page 30: ...Exhaust Devices MAIN CONVERTER FRONT CONVERTER SPLIT AIR PIPE INSULATOR COVERS 97UOF1 507 F1 7 ...

Page 31: ...SENSOR FUEL PUMP RESISTOR RELAY l EC AT CONTROL p OXYGEN SENSOR UNIT I r FRONT CONVERTER l fT CHECK AND CUT VALVE D INHIBITOR Q FUEL J Ell SWITCHES HEADLIGHT SWITCH SWITCH IAiTI V I IV I CHECK VALVE TANK REAR DEFROSTER SWITCH I l r FUEL PUMP 01 FOG LIGHT SWITCH B L_o_w_E_R SW IT_c_H_____________________ M_A_ I_N C 0_ N V E R T E R F U E l F IL T E R __j CJ CJ i m 3 c G D 3 ...

Page 32: ...NTAKE MANIFOLD tt 11 4 ARIABLE JYNAMIC EFFECT INTAKE QAT INDUCTION RESSURE REGULATOR CONTROL BODY A T SOLENOID VALVE VDI WHITE SOLENOID VALVE I RELIEF BLUE SOLENOID VALVE SWITCH GRAY SOLENOID VALVE PAC ORANGE F1 9 ACTUATOR VOl FUEL FILTER 97UOF 1 007 ...

Page 33: ...ION SENS f E J SENSOR AIRFLOW I TER c TH BmE SENSOR 1NARROW 1 1ANGE J VALV GY SD e liD ALliE SWITOil Ill SCLENOIO VALVE fF LIEF H G CCHECTOO GHEEN J P1N1 f 1SQEjjjl_NOIO VALVE 18YPA SS AIH CON HOL liiil POflT AIR SOLENOID t a 68 SCLENOIO VALVE 16 PORT INDUCTION I 0 SOlEI liO VALVE PRESSURE REGULATOH CONTROL sa EN liO VALVE ACCELERATED WARM UP SYSlEMt w SOLENJID VALVE VAAIABL E DYNAMIC EFFECT INTAK...

Page 34: ...i Capac1ty cc cu in n1t1on t1m1ng Test connector green 1 pln grounded J stnbut1on Spark advance e up system Type Type A C D range lass a1r control system afterburn valve Operat1on t1me rpm rpm sec F1 11 138 EGI engine 750 25 for AlT N Range Long l1fe wet Honzontal draft 2 slaj l 3 barrel 45 1 772 45 1 772 X 2 M T 67 77 153 171 or more A T 60 70 140 158 or more 2 700 3 100 70 18 5 15 4 Nylon 6 164 ...

Page 35: ... rpm 97UOF1 509 Jine operation when intake air flows to a port closed by the rotor a pressure wave is created s re wave then goes toward the open intake port compressing the intake air along the way At speed the VOl valve is closed causing the pressure wave path to be long At high engine speed e opens and the pressure wave quickly pressurizes the intake air through the shortened path xced 1nto the...

Page 36: ...MIXING PLATE INJECTOR SECONDARY INJECTOR AIR BLEED SOCKET AIR BLEED SOCKET 97UOF2 508 19 plate is installed at the tip of primary Injector to direct the primary fuel inJection fuel directly into J ke air port F1 13 ...

Page 37: ...TERMEDIATE HOUSING NOTCH The pr1mary inJector is installed noting the following 1 Install the parts in the order shown in the figure 2 Use a new Insulator and 0 rings MIXING PLATE TAB 3 A1 gn 1 re 1abs of the mixing plate with the notches in the intermediate housing F1 14 UDF2 509 ...

Page 38: ...BYPASS PASSAGE INTAKE AIR THERMOSENSOR t CONNECTOR I AIRFLOW METER t 97UOF2 513 eter is changed from a vane type to a linear type The sliding core moves parallel to the airflow Jn there is little air damping and low air resistance as a result of the streamlined shape F1 15 ...

Page 39: ...nsates for certain variations in the output signal of the throttle sensors e tre narrow range throttle sensor is set to output a signal of 20 of full open With the throttle idle on auto adJUSting system the eng1ne control unit will compensate for actual output values of 15 25 e output is less than 15 or more than 25 at idle the engine control un1t fixes the value at 15 and S respectively for fail ...

Page 40: ...TECTION OF ENGINE WARM CONDITION DETERMINA DETECTION OF ENGINE TION NO LOAD CONDITION OF ONLY FOG LIGHT SWITCH LEAN BEST DETECTION OF IDLE ENGINE LOAD CONDITION CONDITION BATTERy FUEL DETECTION OF ENGINE f INJEC IDLE CONDITION TOR I t K DETERMINATION OF LEAN BEST IDLE AMOUNT 97UOF2 515 _ j fuel consumption and reduced exhaust emissions at idle the lean best idle control system is V1th this system ...

Page 41: ...SPARK ADVANCE FEEDBACK AMOUNT 1 I I 50 1 I oo RS rpm DECREASED TS RS rpm INCREASED TS TARGET ENGINE SPEED RS REAL ENGINE SPEED LJ7UOF2 516 To prevent rough idle caused by incorrect idle speeds the spark advance feedback system controls the spark advance The engine control unit judges the engine speed real speed RS and then adjusts the igni tion timmg to obta1n the preprogrammed target speed TS F1 ...

Page 42: ...T adJUStment Not usually necessary unless throttle sensor unit is replaced Th rottle rdle pos auto adjusting system automatically compensates JJustment Not necessary because of lean best idle control system Varrable res eliminated F1 19 ___________________________ ...

Page 43: ...output devices only during a 3 second period after the ignition switch has been turned ON while the test connector is grounded IGNITION COIL WITH IGNITER _ TRAILING SIDE JE LEJ CRANK ANGLE SENSOR G SIGNAL WATER THERMOSENSOR AIRFLOW METER INTAKEAIR THERMOSENSOR AFM INTAKE AIR THERMOSENSOR ENGINE Wu GE 1 THROTTLE SENSOR Q NARROW RANGE PRESSURE SENSOR OXYGEN SENSOR METERING OIL 1 _ 1 o PUMP POSITION ...

Page 44: ... 88 flashes on the digital display and the buzzer sounds for 3 sec after turning the ignition switch ON 6 If 88 does not flash check the check connector wiring 7 If 88 flashes and the buzzer sounds continuously for more than 20 sec check for a short circuit between the engine control unit 1 F terminal and check connector Green 6 pin And check the engine control unit 3X and 3Z terminal voltage Repl...

Page 45: ...osition of the malfunction code represents the number of times the MIL and buzzer are on 0 4 sec during one cycle MALFUNCTION 1 CYCLE CODE ON JU fl CYCLE BREAK ffilll OFF 1 4 0 4 0 4 SEC SEC 4 0 SEC 3 First digit of malfunction code tens position CODE No 03 89lll 4X 565 The digit in the tens position of the malfunction code represents the number of times the MIL and buzzer are on 1 2 sec during on...

Page 46: ...Eng1ne ClfCUit f1xed at 20 C 68 F Throttle sensor Broken w1re short Throttle valve open1ng Jll 1Full range ClfCUit angle input signal f1xed at 20 open Pressure sensor Broken w1re short Intake man1fold pressure J1l 1take man1fold ClfCUII 1nput s1gnal f1xed at 760 Yessure mmHg 29 9 inHg ltmosphenc pres Malfunct1on1ng ECU Atmospheric pressure run u re sensor ATP 1nput s1gnal f1xed at Built 1n ECU 760...

Page 47: ...f Split air solenoid valve I I Soleno1d valve Rel1et j Soleno1d valve Sw1tch I Port a1r soleno1d valve Soleno1d valve Bypass a1r control Soleno1d valve Accelerated warm up system AWS Soleno1d valve 6 port 1nduct1on Soleno1d valve Vanable dynam1c ettect 1ntake VOl I Fuel pump res1stor relay Injector Front secondary InJector Rear secondary I 1 F1 24 I 97UOF1 517 ...

Page 48: ...R ________ SWITCH FOG LIGHT SWITCH t IF EQUIPPED INHIBITOR SWITCH A T 1 IQIIUII ftll 97UOF2066 97UOF1 519 CTOR GREEN 1 PIN Inspection Procedure 1 Warm up the engine to normal operating temperature stop it 2 Connect the SST to the check connector Green 6 pir the negative battery terminal 3 Connect a jumper wire between the test connector G c 1 pin and a ground 4 Turn the 1gnition switch ON then che...

Page 49: ... and 5th sw1tch malfunction Open circuit between Back up l1ght and 5th sw1tch and ECU 1T term1nal overdnve and ground Clutch sw1tch malfunction Open c1rcu1t between clutch sw1tch and ECU 10 term1nal clutch sw1tch and ground clutch switch and ACC circuit 1 lnh1b1tor switch malfunct1on EC AT control ur11t malfunct1on Open C1rcu1t between EC AT control un1t and ECU Headlight sw1tch malfunction Open c...

Page 50: ...OINT F2 13 TURBOCHARGER CONTROL SYSTEM F2 14 SYSTEM CONSTRUCTION F2 14 COMPLETELY IN DEPENDENT TWIN SCROLL TURBO F2 15 TURBO BOOST PRESSURE CONTROL SYSTEM F2 16 CONTROL SYSTEM F2 17 AIRFLOW METER F2 17 THROTTLE IDLE POSITION AUTO ADJUSTING SYSTEM F2 18 LEAN BEST IDLE CONTROL SYSTEM F2 19 SPARK ADVANCE FEEDBACK SYSTEM F2 20 SERVICE POINT F2 21 SELF DIAGNOSIS FUNCTION F2 22 DESCRIPTION F2 22 MALFUNC...

Page 51: ...flow meter L1near type M1x1ng plate Pnmary fuel InjeCtion Completely independent twin scroll turbo Duty solenoid valve Turbo boost pressure control system Throttle idle position auto adjuSting system Lean best Idle control system Vanable resistor elim1nated Spark advance feedback system U Related X Non related Increased horsepower X 0 C X X X F2 2 I Improved performance 0 X X X X 0 Improved Improv...

Page 52: ...BEST IDLE CONTROL SYSTEM IMPROVED FUEL ECONOMY IMPROVED SERVICEABILITY SPARK ADVANCE FEEDBACK SYSTEM IMPROVED PERFORMANCE DUTY SOLENOID VALVE MIXING PLATE INCREASED HORSEPOWER IMPROVED PERFORMANCE IMPROVED FUEL ECONOMY COMPLETELY INDEPENDENT TWIN SCROLL TURBO J INCREASED HORSEPOWER 97UOF2 503 F2 3 ...

Page 53: ...OSPHERIC PRESSURE c SENSOR 5 Jt 1 PRESSURE SENSOR KNOCK SENSOR NEUTRAL SWITCH CLUTCH SWITCH IGNITION SWITCH MILEAGE SENSOR No 1 AND No 2 AIRFLOW METER INCLUDES INTAKE AIR THERMOSENSOR 11 P S PRESSURE SWITCH iff II VATER THERMOSENSOR 1 i l I TEST CONNECTOR GREEN I J BATTERY CRANK ANGLE SENSOR F2 4 1 PIN 97UOF2 504 ...

Page 54: ...LVE AIR SUPPLY VALVE DASH POT DOUBLE THROr _o DIAPHRAGM PURGE CONTROL VAL 0 CHECK CONNECTC GREEN 3 PIN DUTY SOLENOID VALVE TURBO BOOST PRESS CONTROL SOLENOID VALVE PRESSU O REGULATOR CONTROL SOLENOID VALVE SWITCH CHECK CONNECTOR SELF DIAGNOSIS CHECKER GREEN IGNITION COIL WITH IGNITER LEADING F2 5 ...

Page 55: ...Fuel Devices PRESSURE REGULATOR WITH DELIVERY PIPE CHARCOAL CANISTER F2 6 ...

Page 56: ... R E 1 J6 l Exhaust Devices MAIN SILENCER SPLIT AIR PIPE BOCHARGER MAIN CONVERTER FRONT CONVERTER INSULATOR COVERS F2 7 ...

Page 57: ...ITION SENSOR AIRFLOW METER OXYGEN SENSSR WATER THERMOSENS R THROTTLE SENS8R PRESSURE SENS R INTAKE AIR THERMOSENS8R KNOCK SENS R CRANK ANGLE SENSOR CIRCUIT OPENING RELAY HEADLIGHT SW BLOWER SW REAR DEFROSTER SW CANADA SW ECU STAR TER SiGNAL D 0 RELIEF SILENCER SELF DIAGNOSIS CHECKER TEST CONNECTOR GREEN 1 PIN I I FUEL PUMP J J i m s c C 0 s ...

Page 58: ... TE VALVE ACTUATOR SOLENOID VALVE PRESSURE REGULATOR CONTROL ORANGE n SULlNUID VALVE ACCELELATED WARM UP SYSTEM FUEL TANK L VALVE L FILTEA HIGH PRESSURE DUTY ENOID VALVE TURBO BOOST PRESSURE CONTROL rv 3 SOLENOID VALVE RELIEF BLUE 0 c c s I 0 CJ m JJ 0 c i z G c G 0 s ...

Page 59: ... 2 piNJ AI TEJ HAT J l B h FAN SWITCH FUEL PLNP RESISTOR RELAY i h g I II I i l lii l il i INTAKE AIR T FM SENSrn b WATER II c A POSITION flJAIRFLOW I TER TI AJTTLE 5ENSCf1 N lR OW RAtaI THROTTLE 3ENSOR H H j j iil l i i lii liiil ll GY SOLENJIO VALVE SWITCH L SOLENJIO VALVE FB IEF PORT AIR SOLENOID VALVE t u DUTY SOLEI fJIO VAL liE I Tl RKl BOOST PFESSIJE CCNTROLJ i LJ OI SOLENOID VALVE PRESSURE ...

Page 60: ...e Output pressure kPa kg cm2 ps1 Dnve InJeCtion volume cc cu ln 15 sec Operat1on temperature oc F 1 Capac1ty cc cu 1n Jn1t1on t1m1ng Test connector green 1 p1n grounded J stnbut1on Type S Jark advance Type e up system A C 1t1 afterburn valve ercooler Operat1on t1me Type rpm sec F2 11 138 Turbocharged engine 750 25 Long l1fe wet Honzontal draft 2 stage 3 barrel 45 1 772 45 1 772 X 2 55 65 131 149 o...

Page 61: ...STEM MIXING PLATE PRIMARY INJECTOR PRIMARY INJECTOR l b J 97UOF2 508 A mixing plate is installed at the tip of primary injector to direct the primary fuel inject1on fuel directly into the intake air port F2 12 ...

Page 62: ...LEED SOCKET MIXING PLATE INTERMEDIATE HOUSING NOTCH lary injector is installed noting the following the parts in the order shown in the figure new insulator and 0 rings MIXING PLATE TAB he tabs of the mixing plate with the notches in the intermediate housing F2 13 ...

Page 63: ...NOID INTERCOOLER EXHAUST MANIFOLD COMPLETELY INDEPENDENT TWIN SCROLL TURBO FRONT ROTOR 97UOF2 51 0 Two newly developed systems are employed to increase engine horsepower a newly des1gned completely independent twin scroll turbo and a precise turbo boost pressure control system F2 14 ...

Page 64: ...USING INTERMEDIATE HOUSING ROTOR HOUSING SIDE HOUSING 97UOF2 5 ompletely independent twin scroll turbo improves horsepower by utilizing more fully the inherent aves created by the escaping exhaust gases It does this by isolating the gas flow of the front otors as it is directed straight toward the turb1ne wheel The pressure waves are thus used rather ed to mix with the exhaust gases of the opposit...

Page 65: ...EANER 1 DUTY SIGNAL BATTERY DUTY SOLENOlD VALVE SOLENOID 3 ACTUATOR WASTEGATE VALVE 97UOF2 512 1 The duty signal from engine control unit is varied from 5 to 95 based on information from the full range throttle sensor and the crank angle sensor Ne signal The output duty signal is determine within the en gine control unit by the bas1c output duty signal and feedback duty signal 2 The duty signal 1s...

Page 66: ...NTAKE AIR THERMOSENSOR AIR BYPASS PASSAGE INTAKE AIR THERMOSENSOR CONNECTOR c r 1s changed from a vane type to a linear type The sliding core moves parallel to the a _ there is little air damping and low air res1stance as a result of the streaml1ned sr c F2 17 ...

Page 67: ...SOR AIR BYPASS PASSAGE INTAKE AIR THERMOSENSOR CONNECTOR POTENTIOMETER AIRFLOW METER _ meter is changed from a vane type to a l1near type The sliding core moves parallel to the a es1gn there is little air damping and low a1r res1stance as a result of the streamlined sr F2 17 ...

Page 68: ...compensates for certain variations in the output signal of the throttle sensors At idle the narrow range throttle sensor is set to output a signal of 20 of full open W1th the throttle idle position auto adjusting system the engine control unit will compensate for actual output values of 15 25 If the output is less than 15 or more than 25 at idle the engine control unit fixes the value at 15 and 25...

Page 69: ...NIT DETECTION OF ENGINE WARM CONDITION DETECTION OF DETERMINA TION ENGINE NO LOAD OF CONDITION LEAN BEST ONLY FOG LIGHT SWITCH IDLE DETECTION OF ENGINE LOAD BATTER CONDITION CONDITION FUEL DETECTION OF INJEC ENGINE IDLE CONDITION TOR I I i i DETERMINATION OF LEAN BEST IDLE AMOUNT _ fuel consumption and reduced exhaust emissions at idle the lean best idle control s h this system the engine control ...

Page 70: ...CE FEEDBACK AMOUNT I I I 5or ______ __ _ ________ I I oo _ __ RS rpm DECREASED TS RSrpm INCREASED TS TARGET ENGINE SPEED RS REAL ENGINE SPEED 97UOF2516 To orevent rough idle caused by incorrect idle speeds the spark advance feedback system controls the spark advance The engine control unit judges the engine speed real speed RS and then adjusts the igni tlor t ng to obtain the preprogrammed target ...

Page 71: ...TURE ADJUSTMENT e sensor adjustment Not usually necessary unless throttle sensor unit is replaced Throttle idle pas auto adjusting system automatically compensates xture adjustment Not necessary because of lean best idle control system Vanable res eliminated F2 21 ...

Page 72: ...of output devices only during a 3 second period after the ignition switch has been turned ON while the test connector is grounded IGNITION COIL WITH IGNITER r TRAILING SIDE M C EJ CRANK ANGLE SENSOR G SIGNAL KNOCK SENSOR 0 J WATER f7 THERMOSENSOR 0 AIRFLOW METER INTAKEAIR THERMOSENSOR AFM 7 INTAKE AIR THERMOSENSOR ENGINE l L THROTTLE RANGE Q _ __ PRESSURE SENSOR OXYGEN SENSOR METERING OIL PUMP POS...

Page 73: ...een 1 pin and a body ground 4 Turn the ignition switch ON 5 Check that 88 flashes on the digital display and the buzzer sounds for 3 sec after turning the ignition switch ON 6 If 88 does not flash check the check connector wiring 7 If 88 flashes and the buzzer sounds continuously for more than 20 sec check for a short circuit between the engine control unit 1 F terminal and check connector Green 6...

Page 74: ...igit in the ones position of the malfunction code represents the number of times the MIL and buzzer are on 0 4 sec during one cycle MALFUNCTION 1 CYCLE CODE ON __llJl CYClE BREAK OFF _j____ _ 0 4 0 4 SEC SEC 4 0 SEC 3 t S d 9 ot ma tu n on od o on CODE No 03 89U04X 565 c c 2 J 2 Jn d me rnai unc1 Dn cooe represents ne number o1 times tne M l and buzzer are on 1 2 sec during one cycle The MIL and b...

Page 75: ...1re short c1rcu1t Intake a1r temp 1nput m Cng1ne f1xed at 20 C 68 F c SG SCl Bro e11 NI e sllor CI C 11 111 Cl e Jai Je ope111119 f _ R _ uli range angle 1npu s1gnal f1xed at 20 open 13 Pressure sensor Broken w1re short C1rcu1t Intake man1told pressure Ill Intake manifold 1nput s1gnal f1xed at 760 pressure mmHg 29 9 1nHg 4 Atmosphenc pres Malfunct1on1ng ECU Atmosphenc pressure IUI sure sensor ATP ...

Page 76: ...m 31 Solenoid valve Relief rm L 32 Solenoid valve Switch Jrull 33 Port a1r solenoid valve Jf ll1 34 Solenoid valve Bypass a1r control Jl lfilll 38 Soleno1d valve Accelerated warm up system AWS and fffil tiL a1r supply valve ASV 42 Duty soleno1d valve Turbo boost pressure control rrnwn 51 1 Fuel pump res1stor relay runm 71 Injector Front secondary Jmrunlill 73 Injector fiear secondary mnlffil 97UOF...

Page 77: ...ROSTER SWITCH FOG LIGHT SWITCH 4 IF EQUIPPED KNOCK SENSOR 97UOF2 066 97UOF2 065 Inspection Procedure 1 Warm up the engine to normal operating temperature and stop it 2 Connect the SST to the check connector Green 6 pin and the negative battery term1nal 3 Connect a jumper wire between the test connector Green 1 pin and a ground 4 Turn the ignition switch ON then check that the monitor lamp illumina...

Page 78: ...witch and ground I Back up light and 5th sw1tch malfunct1on Open circu1t between back up l1ght and 5th switch and ECU 1T term1nal overdnve and ground Clutch sw1tch malfunction Open c1rcu1t between clutch sw1tch and ECU 10 terminal clutch sw1tch and ground clutch sw1tch and ACC circu1t Headl1ght sw1tch malfunction Open c1rcu1t between headl1ght sw1tch and ECU 3L term1nal headl1ght sw1tch and bat te...

Page 79: ...G ENGINE ELECTRICAL SYSTEM OUTLINE G 2 STRUCTURAL VIEW G 2 SPECIFICATIONS G 4 ALTERNATOR G 5 CHARGING SYSTEM G 5 97UOGX 501 L ...

Page 80: ...OUTLINE STRUCTURAL VIEW NON TURBO ALTERNATOR CRANK ANGLE SENSOR BATTERY IGNITION COIL WITH IGNITER LEADING G 2 STARTER FOR M T IGNITION COIL WITH IGNITER TRAILING STARTER FOR A T SPARK PLUGS 97UOGX 502 ...

Page 81: ...TURBO ALTERNATOR CRANK ANGLE SENSOR l IGNITION COIL WITH IGNITER LEADING HIGH TENSION LEADS STARTER 97UOGX 503 ...

Page 82: ...t KW Voltage v Starter Output No load I Current A Speed rpm Standard mm in Brush length Wear l1m1t mm in G 4 138 EGI Engine MiT i A T 13B_rurbo d Engir1e 12 Negative ground 55023L 60 AH 65023L 55 AH Coldproof area Control Un1t Lead1ng 5 1o ATDC Tralimg 20 2 ATDC at 1dle AIT N range Control un1t Trali1ng NGK BUR9EO Leadmg NGK BUR7EO 14 0 056 12 80 14 1 14 7 w1th temperature grad1ent charactens lcs ...

Page 83: ...GING SYSTEM l I DIODE TRIO IGNITION SWITCH ___j_ BATTERY l j1c REGULATOR ect and control the real battery voltage the sensing for charg1ng rate is changed to a battery vo1 lg type insted of an IC regulator sensing type G 5 ...

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Mazda RX-7 1989, Service Highlights

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