Mazda MPV 1989, B 1989, RX-7 User Manual

RX-7

CONTENTS

•

TITLE

ENGINE LUBLICATION COOLING SYSTEM FUEL AND EMISSION

CONTROL

-----

---

FUEL AND EMISSION

CONTROL ENGINE ELECTRICAL SYSTEM MANUAL AUTOMATIC TRANSMISSION

(ELECTRONICALLY -CONTROLLED) FRONT AND REAR AXLES STEERING SYSTEM BRAKING SYSTEM SUSPENSION BODY 14 BODY ELECTRICAL SYSTEM 15

-

--

---

--

-

SYSTEM

-

SYSTEMS

--- ---

SYSTEMS (TURBO)

--

TRANSMISSION

--

----

(NON-

----

-

--

-

-----

TURBO)

---

--

SECTION

1 2 3

4

5

7

9

10

11

13

•

-

c

ENGINE

e

OUTLINE

OUTLINE OF CONSTRUCTION STRUCTURAL VIEW SPECIFICATIONS INTERCHANGEABILITY

TENSION BOLT FRONT COVER ROTOR

..................................................

................................

....................................

............................

........................................

.........................................

....................................................

.................

C-

CC-

C-

CC-

97UOCX

2

2 2

4

5

6

7 8

501

e

OUTLINE

OUTLINE OF CONSTRUCTION

The 13B improved engine performance.

Major changes

1.

Rotor : Lighter, rotor recess shape change to increase compression ratio

2.

Tension bolt : Strengthening ribs added

3.

Front cover : Shape changed for new metering

4.

Side housings : Inlet port erea enlarged

STRUCTURAL VIEW

HOUSING-RELATED PARTS

in

the 1989

RX-7

is

basically the same as

FRONT HOUSING

in

the previous model but with some modli

oil

pump

FRONT ROTOR HOUSING

c:=:-

_

FRONT OIL SEAL

._)

REAR HOUSING

REAR ROTOR HOUSING

INTERMEDIATE HOUSING

C-2

·-

97UOCX·502

;:;'"'TA

~

TING-RELATED

PARTS

BALANCE WEIGHT

ECCENTRIC PULLEY

REAR ROTOR

' •

FRONT ROTOR

DRIVE PLATE

COUNTER WEIGHT

FLYWHEEL

-.

C-3

SPECIFICATIONS

cc

Model

(cu

1n)

Item

Eng1ne type Rotary eng1ne

Displacement

Number

Combustion

Compression

A1r

Port

of cyl1nders and

chamber

Induction

t1m1ng

rat10

Intake

Exhaust

arrangement

type

Open

Close

Open

Close

Pnmary 4S0 ATOC

Secondary Auxiliary Pnmary

Secondary

Auxil1ary

Turbo Non-Turbo

6S4 X 2 (40.0 X

2 rotors. longitudinal

Bathtub

9.0 1

4 port

1nduct1on

32°

ATOC

S0°

ABOC

soo

ABOC

0

7S

BBDC

48°

ATOC

2)

6 port

32°

4S

40°

30°

80"

9.7 1

1nduct1on

ATOC

0

ATOC

ABOC

~~

\

Fuel

supply

lgn1t1on (Green

Idle grounded)

t1ming

1-p1n)

speed

system EGI

(w1th

grounded)

(w1th

test

connector

(Green

Tra1l1ng

Lead1ng

1-pln)

rpm

± 2 ' ATOC (REO)

20°

so

±

1 o ATOC (YELLOW)

750 ± 25

l,~

97UOCX 504

C-4

INTERCHANGEABILITY

:::

,.,,ng

chart shows interchangeability of major components of the previous model and the 1989 mode'

X Not interchangeable

...

ousmg-

·~

ated

;:.a

r1S

;;

:~at1ng-

-~

a~ed

=~~s

Part

Front rotor hous1ng Rear rotor hous1ng

Front

hous1ng

i ntermed1ate housing

Rear housing

seal1ng

nner

Outer sealing rubber Front cover Orl

pan Tens1on ::ccentnc shaft

Rotor

~~pex

S de

seal

:::orner

3a',ance weight I

J I pump dnve sprocket

: :centr1c

'C

=centnc shaft bypass valve - -

~

. ·ey lock bolt

~

.

:.

heel

• · beanng .1ter

rubber

bolt

seal

shaft pulley t

(MIT)

we1ght

(A/T)

-1

. -

i

---1

I

+

J

-~·

.

l

I,

Interchangeability

X

0

X

0

X

0

X

0 0

0

X

0

X 0 0

X

0

X

Remark

• Knock sensor boss added

• Inlet port area enlarged

• Shape changed to Incorporate new

tng

Oil

pump

• Ribs added

•

We1ght

•

Combustion chamber shape changed

• Shape changed

•

We1ght

•

Shape changed

•

We1ght

'

to

center of shank

reduct1on

metw

•

C-5

TENSION BOLT

...

OTHERS

No.18 BOLT

(}1

T

STRENGTHNING RIBS

128 ± 2mm

HEAT-SHRINK PROTECTOR

lllllllllllllllllllllllllllllll

(5.04 ± 0.08 in)

NOTE No.1? SOL OTHERS. THERE IS AN IDENTIFICATION

The strength of the tension bolts The tension transmiss1on of eng1ne noise. To reduce this noise. the heat-shrik protector through the intermediate housing boss. The No. 18

protector). shrunk

bolt installed into the No. 18 hole differs from others

If

the bolt

w1th

a l1ghter or match.

T IS LONGER THAN

MARK.

1s

increased by addit1on of strengthening ribs

is

reused and the protector

No.18 BOLT

bolt

is

damaged, replace the protector. The protector

C-6

in

that

is

supplied as an assembly (bolt

in

the middle of the shank.

it

is

not fully enclosed. lead1ng to

is

used on the bolt where

w1th

washer and

97UOCI 506

1t

goes

1s

easily

,

.•

FRONT COVER

FRONT COVER GASKET

FRONT COVER

~.

~BACKUP

0-RING

RING

•

~

· 989

:::::ded

RX-7

front cover

between the front cover and front housing for improved sealing.

is

changed to incorporate a new metering

C-7

oil

97UOCX 507

pump.

ROTOR

TURBO

RIBS

NON-TURBO

RIBS

~

\

A

/J

I

c--~~

v

A A

~

A~

1 0.9mm (0.43 in)

,_

4

8.8mm (0.35 in)

r---/1

~-

The rotor

9.7 : These improvements The rotor ribs are redesigned for increased strength. The combustion chamber rotor recess

The rotor for turbo and non-turbo engines are distinguished by the rotor recess shape.

in

the 1989

1 for non-turbo model) than the previous engine.

RX-7 results

is

lighter and provides a higher compression ratio (9.0 : 1 for turbo model and

in

a engine with more power and torque.

1s

made more uniform by utilizing a mechanical cutting process.

97UOCX 508

C-8

...

D

LUBRICATION SYSTEM

OUTLINE

OUTLINE OF CONSTRUCTION STRUCTURAL VIEW SPECIFICATIONS INTERCHANGEABILITY

METERING OIL PUMP

OUTLINE OPERATION FAIL-SAFE FUNCTION

SERVICE POINT

OIL FILTER

..................................................

................................

....................................

............................

...............................

...............................................

...........................................

.............................

.......................................

............................................

.................

D-

DDD-

D-

97UODX 501

2

3

4

4 5 5

6

-

OUTUNE

OUTLINE OF CONSTRUCTION

-~e

lubncation system of the 1989

"lents have been made

1 A new electronically controlled metering

oil

pump for reduced

2 A smal!-size

oil

filter

as

described below.

oil

consumption and improved reliability.

is

used and

STRUCTURAL VIEW

RX-7

its

installation procedure

is

basically the same

oil

pump

is

adopted instead

as

the previous model. but some improve-

of

the previous mechanical metering

is

different.

MANIFOLD OIL NOZZLE

TURBOCHARGER

HOUSING

0-2

SPECIFICATIONS

Items

Lubncat1on system

Type

011

pump

Control valve relief pressure

Oil cooler

Regulator valve

Oil filter

Eccentnc shaft bypass valve

Oil

capaCity

Eng1ne

oil

(API

Number

1

1 D1ameter x

Type

Rel1ef

Type

Rel1ef

Total (dry

011

Oil cooler

011

serv1ce)

of rotors

w1dth

temperature pressure dlfferent1al kPa

rel1ef

pressure kPa

pressure

eng1ne)

pan

filter , actory-1nstalled l1ters

(US qt Imp qt) i Serv1ce parts

of rotor

d1fferent1al

rel1ef

temperature

Engine model

kPa (kg/cm

(kg/em'.

kPa

(kg/em'.

l1ters

(US qt. Imp qt)

liters

(US qt. Imp qt)

l1ters

(US

\ F

I

qt

_____

mm

2

oc

Imp

.

ps1)

(°F)

ps1)

(°F)

(1n)

ps1)

qt)

_[_________

50 X 17.5

Turbo

(1

97 X

A1r

349

Fuel

Force-fed

Trocho1d

069)

1.079 (11.0.

cooled.

60-65

(140-149)

(3

56. 50) 490 (5.0. 71)

Full flow.

98

60 (140) or below

5.8 (6 1 5.1)

4.4 (4.7. 3

0.85 (0.90. 0

0.19 (0.20 0 17)

0.17 (0.18. 0 15)

eff1c1enr·

2

50 X 12.5 (1.97 X 0.49)

156)

w1th

bypass valve

or below

at

60°C

paper

element

(1.0. 14)

9)

75)

SF

(M1neral oil only)

Non-Turbo

(140"F)

----

___

97UODX

_j

507

INTERCHANGEABILITY

The following chart shows interchangeability of major components of the previous model and the 1989 model.

Interchangeable X Not Interchangeable

Interchangeability

X

______________________________

Remark

Oil

pump

unchanged

Baffle plate for turbo model Shape

changed Small-s1ze filter used

Shape

changed

el1m1nated

97UODX

j

503

011

pump

rl1eterlllg 0 I

f1lter

--1ous1ng

J

_c_o_o_le_r

Part

oil

pump

oil

nozzle Shape cr1anged

______________

~

0-3

METERING OIL PUMP

OUTLINE

An electronically controlled metering oil

pump The ECU bases It

then sends a pulse signal to control the

for reduced

it

calculation of engine

oil

consumption. This new metering

temperature and intake air amount (load condition). The same metering

TURBO

oil

pump

is

used for turbo and non-turbo engines, but the

HOUSING OIL NOZZLE

oil

pump

is

used instead of the previously used mechan1cal metering

oil

needs on the input from various sensors.

oil

discharge amount according to engine speed,

oil

pump

is

controlled by the

oil

nozzle plumbing

eng1ne

control unit.

coolant

1s

different

...

~

MANIFOLD OIL NOZZLE

NON-TURBO

~

I

NON-TURBO

0-4

97UODX·504

OPERATION

The

oil

discharge mechanism

the previous mechanical metering

is

ing worm, which

The

oil

discharge amount

The plunger rides against the taper

changes to Stepping motor operation

the optimum

control the

oil

driven by the eccentric shaft.

oil

discharge for

in

the new electronically controlled metering oil pump

oil

is

controlled by movement

discharge amount.

is

monitored by the

all

driving conditions.

is

the same

pump. The plunger and differential plunger are driven through the driv-

of

the control pin.

pos1t1on

the control

As

the

sensor, which results

p1n.

p1n

moves up or down, the plunger stroke

in

the engine control unit setting

STEPPING MOTOR

as

that

/

in

CONTROL PIN

f

OIL

DRIVING WORM

DIFFERENTIAL PLUNGER

FAIL-SAFE FUNCTION

If

the engine control unit senses a malfunction of the stepping motor or

place.

takes

The engine control unit fixes the control pin to tion to engine speed The

vehicle can be driven normally

step range.

' the

oil

injection needs exceed the lowest compensation step range. fuel injection

~1gine

speed and resultant oil injection requirements.

only without any load compensation.

as

long

its

lowest compensation step, and

as

the

oil

injection needs are within the lowest compensation

D-5

posit1on

SUB-PLUNGER

97UODX 505

sensor. fail-safe function

oil

is

discharged

is

restricted to limit the

in

propor-

SERVICE POINT

OIL FILTER

The 1989 The service oil filter

RX-7

has a small-size

is

oil

filter. The factory-installed oil filter differs from the service parts oil filter.

the same as that used for the Mazda 323 B-series engine. '

.....

Oil filter capacity

ctory 1nstalled

rvice part

-

--·-----·-----

019

0.17

(0.20, 0.17) (0

18.

0.15)

liters (US qt,

_,]

Imp

qt)

97UODX 508

Replacement

1.

Remove the oil filter with a suitable wrench.

2.

Use a clean rag to wipe clean the mounting surface on the engine.

3.

Apply a small amount of clean engine oil to the rubber seal of the new filter.

4.

Hand tighten the oil filter until the rubber seal contacts the base, and then tighten the filter an additional 1-1/6 turn with a wrench.

5.

Start the engtne and inspect for leaks around the filter seal. ·

6.

Check the oil level and

add

oil as necessary.

.J

0-6

COOLING SYSTEM

E

OUTLINE

OUTLINE OF CONSTRUCTION STRUCTURAL VIEW SPECIFICATIONS INTERCHANGEABILITY

COOLING FAN WATER PUMP THERMOSTAT

RADIATOR

..................................................

................................

....................................

............................

..........................................

...............................................

..................

E-

EEE-

E-

EEEE-

97UOEX 501

2

2 2 3

3

4 5 6 7

-

OUTLINE

The cooling system of the 1989 have been

1.

The number of cooling fan blades

2.

In

3.

A new radiator with a filler

4.

In

STRUCTURAL VIEW

OF

CONSTRUCTION

RX-7

is

basically the same as the previous model but certain improvements

made conJunction with the cooling conjunction with the radiator modification, the thermostat cover and thermostat gasket shapes are changed.

as described below.

fan

modification, the shape of the water pump

cap

body

is

increased from 8 to 1 0 for improved cooling performance.

is

changed for improved rigidity.

is adopted for improved serviceability.

THERMOSTAT

~

WATER PUMP

RESERVOIR

FROM HEATER

(/

fj

ELECTRIC

COOLING

FAN

FAN RELAY

RADIATOR CAP

FILLER CAP BODY

DRAIN PLUG

E-2

97UOEX-502

SPECIFICATIONS

nts

Item

Cool1ng

Coolant capac1ty

/Vater

Tl1ermostat

Rad1ator

'ller

Cool1ng fan

method

pump

cap

W1th

heater

Type

Pulley

rat1o

Type

Open1ng

Full

[

Type

Relief pressure

Type

Number

Outer

Type

temperature

ope'l

open

of blades

d1ameter

liters (US qt.

(speed)

temperature

l1ft

Engine

kPa

mode~

Imp

°C

oc

mm

2

(kg/cm

•

mm

qt)

(°F) i

(oF) i

(1n)

ps1)

(1n)

Turbo

Water-cooled,

8.7 (9.2 7.7)

forced

Ce'ltnfugal

Non-Turbo

c1rculat:o'l

7.3

(7

7 c

~

1 1.22

Wax. bottom

I

80.5-83.5

95

I

8-10

Corrugated

74-103

(0.75-1.05.

Thermo-modulated

bypass

(177

-182)

(203)

(0.31-0.39)

f1n

11-15)

10

390

(15 35)

Electncal

-

mm

w

(1n)

255

90

5

(10.04)

:

(;CtriC

COOling

i Capac1ty

Number

Outer d1ameter

of blades

INTERCHANGEABILITY

~.

;co

following chart shows the major components interchangeability between the previous model

· ?39 model.

· ·_?•changeable

· ":Jstat

:

c::or

:

:::Jr

cap

'lQ fan

Parts

X

Not

Interchangeable

Interchangeability

X

c

X

Shape

Rubber

Shape

Blade

changed

gasket used

changed

number

Increased

Remark

c:·

)02

··::

::ooling fan

0

E-3

COOLING FAN

FAN DRIVE

The thermomodulate cooling fan used

in

the 1989 RX-7 has 10 blades and a blades and double bearing of the previous model, which result ing fan drive characteristics cause the water

pump

is

the same as the previous model but the fan-dr1ve

shaft bearing mounting diameter

is

larger.

E-4

s1ngle

in

improved cooling performance. The cool-

bear1ng 1nstead of 8

1s

not Interchangeable be-

•_/

WATER PUMP

SHAFT BEARING

PULLEY BOSS

\

BEARING HOUSING

@~

EXTRA RIBS

I

WATER

WATER PUMP BODY

PUMP GASKET

"'

\ -

-

97UOEX

:.

:=::er

pump shape

•.

·-g

housing : Extra ribs are used for improved rigidity.

·-.·

:Jump gasket : The shape

...

:::earing and pulley boss : The shaft bearing shaft outer diameter and pulley boss inner diameter are

·.

· :Jump body : The body shape

·-=-·~al

parts are interchangeable with the previous

is

changed to incorporate the new cooling fan and thermostat.

is

changed because of the bearing housing change .

increased to incorporate the new

is

changed to incorporate the new thermostat and cover. The water thermoswitch for automatic transmission and Turbo is

in

the

pump

body.

RX-7.

cooling fan.

models

E-5

505

THERMOSTAT

RUBBER GASKET

JIGGLE

A new thermostat with a rubber gasket same

as

the prev1ous model. The outer diameter

use

w1th

the rubber gasket.

Assemble the rubber gasket with the notch positioned around the Jiggle valve

is

used for improved serviceability. The open1ng temperature

VALVE

is

decreased from 54mm (2.13

1n)

to 52mm (2.05

is

in)

the

for

E-6

'

RADIATOR

..

RADIATOR CAP

FILLER CAP BODY

RADIATOR

-

.:::::of

the radiator core

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

, - bleeder plug and the filler cap at the thermostat cover

':'j

is

decreased (width

561

.Smm (22.12

E-7

in)

x height 415mm (16.34

is

eliminated. Coolant replacement

in)

cap

body, the need

97UOEX-507

x thickness

is

done

F1

•

FUEL

AND

EMISSION

CONTROL SYSTEMS

{NON-

OUTLINE

OUTLINE OF CONSTRUCTION EMISSION CONTROL SCHEMATIC

DIAGRAM

SYSTEM DIAGRAM

VACUUM WIRING DIAGRAM SPECIFICATIONS

VARIABLE DYNAMIC EFFECT INTAKE

(VDI) SYSTEM

FUEL SYSTEM

MIXING PLATE SERVICE POINT

CONTROL SYSTEM

AIRFLOW METER

THROTTLE-IDLE-POSITION AUTO-

ADJUSTING SYSTEM

LEAN BEST-IDLE CONTROL SYSTEM SPARK ADVANCE FEEDBACK SYSTEM SERVICE POINT

SELF-DIAGNOSIS FUNCTION

DESCRIPTION

MALFUNCTION

SWITCH MONITOR FUNCTION

................................................

...........................................

HOSE ROUTING DIAGRAM

.......................................

........................................

......................................

.......................................

TURBO)

................

................................

.......

.................................

...................................

....................................

.................................

..................................

...........................

.......

....................................

...................

CODE

NUMBER

................

.............

....

'J7UOII

F1F1-

F1F1F1F1-10 F1-11

F1-12 F1-13 F1-13

F1-14 F1-15 F1-15

F1-16

F1-17

F1-18 F1-19 F1-20

F1-20

F1-21

F1-25

c,[11

2 2

4 8

9

•

OUTLINE

OUTLINE OF CONSTRUCTION Development

The

development concepts for the new model are

1.

Increased horsepower

2.

Improved performance

3.

Improved fuel economy

4.

Improved serviceability

Concepts

as

follows

Areas of

Improved parts

Airflow

M1x1ng

Vanable

Throttle-1dle-pos1t1on auto-adJUSting system

Lean best (Vanable res1stor el1m1nated)

Spark '.

Related X

Improvement

Development concepts

meter

(L1near type)

plate

(Pnmary

dynam1c effect 1ntake (VOl) system

1dle

advance

fuel

1nJ8ct1on)

control system

feedback

Non

system

horsepower

X

Improved

performance

X

Improved

fuel

I

economy

X

X X

X

Improved

serviceability

X

97UOF1 502