Mazda RX-7 Engine Removal, Overhaul and Installation: fuel system, ignition system and more

Mazda RX7 1993-1995 FD3S

On models with anti-theft radio, obtain code number and deactivate anti-theft system before disconnecting battery cable.

IGNITION SYSTEM

Mazda RX7 is equipped with distributorless ignition system.

DISTRIBUTOR REMOVAL AND INSTALLATION

Disconnect negative battery cable. Move any hoses, wiring or components interfering with distributor removal. Reference mark high tension wires to distributor cap and disconnect all wiring from distributor. Remove distributor cap. Remove hold-down bolt and distributor. To install, reverse removal procedure. Adjust ignition timing.

Overhaul
On all distributors, internal parts are not available. If faulty replace complete distributor. Only cap, rotor and seal are available. See Fig. 1 .

Fig. 1: Exploded View Of Distributor (Typical)
Fig.1

CRANKSHAFT POSITION SENSOR REMOVAL AND INSTALLATION

Disconnect negative battery cable. Remove drive belt. Remove crankshaft pulley and crankshaft position sensor plate. Remove nuts and sensor bracket. Disconnect electrical connectors. Remove sensor assembly. To install, replace sensor assembly and install mounting nut. Using a feeler gauge, ensure sensor air gap is .040-.080" (1.0-2.3 mm). To complete installation, reverse removal procedure. Tighten bolts to specification.

FUEL SYSTEM

WARNING: Always relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components.

FUEL SYSTEM PRESSURE RELEASE

1. Start engine. Disconnect fuel pump relay or circuit opening relay.
2. Allow engine to run until it stalls. Turn ignition off. Reconnect electrical connector.

FUEL PUMP/CIRCUIT OPENING RELAY LOCATION

Mazda RX7 1993-1995
- Location: Underhood Fuse Block

FUEL SYSTEM PRIMING

CAUTION: After performing fuel system repairs, use following procedure to prime fuel system before starting engine. This prevents excessive engine cranking and allows system to be leak-tested.

Connect jumper wire between GND and F/P terminals of data link connector. See Fig. 2. Turn ignition on for about 10 seconds and then off. Disconnect jumper wire.

Fig. 2: Identifying Data Link Connector Terminals
Fig.2

FUEL PUMP

CAUTION: After performing fuel system repairs, prime fuel system before starting engine.

Removal
1. Release fuel pressure.
2. Remove carpet in luggage compartment.
3. Remove fuel pump access cover. Disconnect fuel hoses and electrical connector. Remove fuel pump and sending unit assembly. Remove fuel pump from assembly.

Installation
1. Install fuel pump to assembly using NEW "O" ring, cap and spacer between fuel pump and outlet pipe (coat "O" ring with oil or gasoline before installing). See Fig. 3 . After installing fuel pump to assembly, blow into fuel pump outlet pipe toward pump to confirm sealing of "O" ring, air should not pass.
2. If air flows through pump, shake pump several times to ensure check ball is not jammed. To complete installation, reverse removal procedure.

Fig. 3: Installing Fuel Pump
Fig.3

FUEL PRESSURE REGULATOR: REMOVAL AND INSTALLATION

CAUTION: After performing fuel system repairs, prime fuel system before starting engine.

1. Disconnect negative battery cable. Release fuel system pressure.
2. To install, reverse removal procedure. Install NEW gasket and "O" ring (if equipped).

FUEL RAILS AND INJECTORS: REMOVAL AND INSTALLATION

CAUTION: After performing fuel system repairs, prime fuel system before starting engine.

1. Release fuel pressure.Remove air intake duct. See Fig. 4 . Remove the throttle body.
2. Remove upper intake manifold. Disconnect fuel hoses from fuel rail. Disconnect injector electrical connectors. Remove idle speed control solenoid. Remove fuel rail and injectors as an assembly. Remove insulators, injectors and "O" rings from fuel rail.
3. To install, reverse removal procedure. Apply coat of engine oil to NEW "O" rings, and install rings on injectors. Install NEW insulators. Tighten fuel rail mounting nuts to specification. Install NEW manifold gaskets.

Fig. 4: Exploded View Of Air Intake System
Fig.4

OXYGEN SENSOR

Removal
Disconnect oxygen sensor electrical connector. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). If sensor is difficult to remove, use rust penetrant to avoid damaging threads. Carefully remove sensor.

Installation
Apply anti-seize to sensor threads (if reusing old sensor or if new sensor is not coated with anti-seize). Install sensor and tighten to specification. Reconnect sensor electrical connector.

THROTTLE BODY: REMOVAL AND INSTALLATION

CAUTION: After performing fuel system repairs, prime fuel system before starting engine.

1. Disconnect negative battery cable. Remove air intake tubes.
2. Disconnect accelerator cable, coolant hoses and electrical connectors from throttle body as necessary.
3. Install NEW throttle body gasket. To complete installation, reverse removal procedure.

TURBOCHARGER

Removal
1. Raise and support vehicle. Drain coolant. Disconnect negative battery cable. Remove air cleaner, intake air hoses and pressure chamber. See Fig. 5. Remove air control valve assembly. Disconnect vacuum hoses.
2. Remove drive belt and air injection pump. Disconnect oxygen sensor, exhaust down pipe and catalytic converter. Disconnect turbo control valve rod and actuator. See Fig. 5. Disconnect oil pipes from turbocharger. Remove coolant hoses.
3. Remove bolts securing turbocharger to exhaust manifold. Remove turbocharger assembly.

Installation
Install turbocharger with NEW gaskets, "O" rings and exhaust manifold studs. Tighten nuts and bolts to specification. See Fig. 6. To complete installation, reverse removal procedure. Prime oiling system.

Fig. 5: Exploded View Of Turbocharger Assembly
Fig.5

Fig. 6: Installing Turbocharger
Fig.6

TORQUE SPECIFICATIONS

Distributor Mounting Bolts: 14-18 (19-24) Ft. Lbs (N.m)
Fuel Rail Mounting Bolt/Nut: 14-18 (19-24) Ft. Lbs (N.m)
Oxygen Sensor: 22-36 (30-49) Ft. Lbs (N.m)
Throttle Body-To-Manifold Bolts: 14-18 (19-24) Ft. Lbs (N.m)
Turbo-To-Exhaust Manifold Bolts/Nuts
- "A" Bolts: 28-38 (38-51) Ft. Lbs (N.m)
- "B" Nuts: 16-21 (22-29) Ft. Lbs (N.m)
- "C" Nuts: 32-42 (44-57) Ft. Lbs (N.m)
Turbo-To-Exhaust Pipe Nut: 28-38 (38-51) Ft. Lbs (N.m)
Upper Intake Manifold Bolt/Nut: 14-18 (19-24) Ft. Lbs (N.m)
Crankshaft Position Sensor Bolt: 71-97 (8-11) INCH Lbs. (N.m)
Fuel Pressure Regulator Bolts: 71-97 (8-11) INCH Lbs. (N.m)
Turbo Oil Return Pipe Nut: 71-97 (8-11) INCH Lbs. (N.m)

Did you find this repair info helpful or are improvements needed? Please leave comments below.

Mazda RX7 1993-1995 FD3S

Garage411 : EngineRemovalInstallationFD3S