Garage411 : TurboRotory13BFD3S



Mazda RX7 1.3L Turbo Rotary Engine Overhaul: intake, exhaust manifolds, rotors, engine lubrication and more

Mazda RX7 1993-1995 FD3S

ENGINE IDENTIFICATION


Engine can be identified by engine model and number. Engine model and number are stamped on left front of engine, below generator.

ENGINE IDENTIFICATION CODE

REMOVAL AND INSTALLATION


CAUTION: When battery is disconnected, radio will go into anti-theft protection mode. Obtain radio anti-theft protection code from owner prior to servicing vehicle.

For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE AND PRIMING

Releasing Pressure
Locate and remove fuel pump relay from underhood fuse box. Start engine and allow to stall. After engine stalls, attempt to restart engine to ensure no residual pressure exists. Turn ignition off and reinstall fuel pump relay. When disconnecting fuel hoses, cover connection with shop rag to catch fuel leakage. To avoid excessive cranking after servicing, prime fuel system before starting engine.

Priming System
Ensure fuel system is closed. Connect jumper wire between FP and GND terminals of data link connector. See Fig. 1. Turn ignition on for about 10 seconds and check for fuel leaks. Turn ignition off and disconnect jumper wire.

Fig. 1: Identifying Data Link Connector Terminals (Typical)
Fig.1
COOLING SYSTEM BLEEDING
CAUTION: If engine overheats during procedure, system contains excessive air. Stop engine and allow it to cool, then repeat step 1).

1. Slowly pour coolant into radiator at a rate of 1.1 qt. (1.0L) per minute maximum until coolant is level with filler port. Fill coolant reservoir to "F" mark. Securely install radiator cap. Start engine.
2. Operate engine at idle until normal operating temperature is reached. If coolant level warning light illuminates during warm-up, turn engine off and check drain plug and coolant hoses for leaks. Operate engine at 2200-2800 RPM for 5 minutes. Stop engine and allow to cool.
3. Repeat steps 1) and 2). Check coolant level. If engine coolant is not level with filler neck, repeat entire procedure. If engine coolant is level with filler neck, fill reservoir to "F" mark.

ENGINE

Removal
1. Release residual pressure from fuel system. Mark and remove hood. Remove battery and tray. Remove engine undercover. Drain engine oil and coolant. Remove air intake duct, air cleaner and hoses. Remove engine compartment strut bar. Disconnect radiator hoses and heater hoses.
2. Mark and remove throttle cable and cruise control cable. Remove underhood fuse box mounting bolts. Move underhood fuse box aside with harness attached. Mark and disconnect necessary electrical connectors and vacuum hoses. Disconnect and plug fuel hoses. Remove drive belts. Remove power steering pump and AC compressor with hoses attached and support aside.
3. Disconnect oil pipes from oil cooler. Remove exhaust pipe and turbocharger heat shields. Remove exhaust head pipe. On AT, disconnect transmission cooler pipe from lower radiator tank. Remove bolt securing transmission cooler pipes. Remove torque converter-to-flexplate bolts.
4. On all models, remove starter assembly. Remove transmission-to-engine bolts. Remove engine mount nuts. Remove engine out through top of vehicle.

Installation
To install, reverse removal procedure. Tighten bolts and nuts to specification. Fill all fluids to correct level. Prime fuel system before attempting to start engine. Bleed cooling system.

INTAKE MANIFOLD

Removal
1. Release residual pressure from fuel system. Drain coolant. Disconnect negative battery cable. Remove fresh air duct, air cleaner, intake air hoses and pressure chamber. See Fig. 2 . Remove air by-pass valve. Remove air intake pipe. Remove coolant hose from throttle body. Disconnect vacuum hoses.
2. Remove accelerator cable, cruise control cable and throttle body assembly. Remove upper intake manifold bolts and upper intake manifold.
3. Disconnect fuel hose from injector fuel rail. Disconnect vacuum hoses at intake manifold. Disconnect fuel injector wire harness connector. Remove intake manifold-to-engine bolts and remove intake manifold. Installation To install, reverse removal procedure. Use NEW gaskets. Tighten nuts and bolts to specification.

Fig. 2: Exploded View Of Air Intake System
Fig.2

TURBOCHARGER/EXHAUST MANIFOLD

Removal
1. Raise and support vehicle. Drain coolant. Disconnect negative battery cable. Remove fresh air duct, air cleaner, intake air hoses and pressure chamber. See Fig. 2 . Disconnect accelerator cable from throttle body. Disconnect all necessary vacuum hoses.
2. Remove drive belt and air injection pump. Disconnect oxygen sensor, exhaust downpipe and catalytic converter. Disconnect turbo air control valve assembly. See Fig. 3 . Disconnect oil pipes from turbocharger. Remove coolant hoses.
3. Remove any remaining vacuum or air hoses. Remove turbocharger-to-exhaust manifold bolts/nuts. Remove turbocharger assembly from vehicle. Place turbocharger assembly on bench and disassemble as necessary.

Installation
Install turbocharger with NEW gaskets, "O" rings and exhaust manifold studs. Tighten nuts and bolts to specification. See Fig. 4 . To complete installation, reverse removal procedure. Prime oil system.

Fig. 3: Exploded View Of Turbocharger Assembly
Fig.3

Fig. 4: Installing Turbocharger
Fig.4
REAR ECCENTRIC SHAFT OIL SEAL

Removal
Disconnect negative battery cable. Drain engine oil. Remove transmission. On vehicles with manual transmission, install Ring Gear Brake (49-F011-101), or on vehicle with automatic transmission, install Counter Weight Stopper (49-1881-055). On all models, using Flywheel Box Wrench (49-0820-035), remove flywheel/counterweight. Using Oil Seal Remover (49-0813-225), remove rear oil seal.

Installation
Apply engine oil to lip of new seal and install in rear cover. Install oil seal flush with edge of rear cover. To complete installation, reverse removal procedure. Tighten lock nut to 290-360 ft. lbs. (393-490 N.m).

WATER PUMP

Removal
1. Remove battery and battery tray. Remove fresh air duct, air cleaner and intake air hoses. Remove radiator drain plug and drain coolant. Remove water pump drive belt. Remove water pump pulley.
2. Remove generator and air injection pump. Remove upper radiator hose. Remove charge air cooler (intercooler), air separation tank and related brackets. Remove lower radiator hose and by-pass hoses from water pump.
3. Disconnect metering oil tube. Remove water pump bolts and nuts and remove water pump. Disconnect engine coolant temperature switch connector.

Installation
To install, reverse removal procedure. Tighten water pump nuts to 13-20 ft. lbs. (18-26 N.m). Tighten drive belts and refill coolant.

OIL PAN

Removal
1. Disconnect negative battery cable. Raise and support vehicle. Remove splash shield. Drain engine oil. Remove stabilizer bar. Support engine using Engine Mount Bracket (49-G017-5A0).
2. Remove engine mount-to-crossmember nuts. Disconnect power steering oil pipes at steering gear and mounting bracket on crossmember. Remove steering gear mounting bolts. Disconnect lower control arms from steering knuckles.
3. Remove crossmember-to-chassis bolts. Remove crossmember from vehicle. Remove engine mounts from engine. Remove oil pan mounting bolts. Insert knife or screwdriver between oil pan and engine and carefully loosen oil pan from engine. Remove oil pan.

CAUTION: If reusing old oil pan bolts, remove old sealant from bolt threads. Failure to remove old sealant may result in cracked block at bolt holes.

Installation
To install, reverse removal procedure. Ensure all old sealant is removed from oil pan bolts. Apply continuous bead of silicone sealant to oil pan flange, running sealant bead inside bolt holes. Install oil pan within 5 minutes of applying sealant. Tighten oil pan bolts to 79-104 INCH lbs. (9-12 N.m). Tighten engine mounts to 55-69 ft. lbs. (75-93 N.m). Fill engine with oil to specification.


OVERHAUL


DISASSEMBLY
Disassembly procedures are with engine removed from vehicle.

1. Remove all external components, oil pan bolts, oil pan and oil strainer. While holding flywheel/counterweight, remove lock bolt on front of eccentric shaft. Remove "O" ring, by-pass valve and spring. See Fig. 5. Remove eccentric shaft pulley, crankshaft position sensor plate and pulley hub.
2. Remove front cover. Remove oil control valve from front cover. Remove oil pump sprockets and chain. Remove oil pump. Remove counter balance weight, Woodruff key, needle bearing and spacer. See Fig.5.
3. On vehicles with manual transmission, install Ring Gear Brake (49-F011-101), or on vehicles with automatic transmission, install Counter Weight Stopper (49-1881-055). On all models, using Flywheel Box Wrench (49-0820-035), remove flywheel/counterweight. Loosen tension bolts gradually in sequence. See Fig. 6. Remove tension bolts.

Fig. 5: Exploded View Of Front Cover and Components
Fig.5
Fig. 6: Loosening Sequence Of Tension Bolts
Fig.6
CAUTION: Keep all apex, side and corner seals matched and in respect to numbers near each groove on rotor face. See Fig. 7 .

4. Remove rear housing. If seals stick to rear housing, remove and place them into their original position. Remove rear oil seal from rear housing. See Fig. 8. Remove rear stationary gear. Remove oil regulator valve, oil pressure switch and temperature sender from rear housing.
5. Using a small slide hammer, remove tubular dowel from rear rotor housing. Before removing rear rotor housing, remove side pieces from rear rotor, keeping them in order. See Fig. 23. Carefully lift off rear rotor housing. Remove "O" ring from dowel hole. Remove rear rotor seals and springs, keeping them in order. Mark rear rotor for reassembly.

CAUTION: DO NOT place rotor assembly on a hard surface.

6. To remove rear rotor, rock rotor back and forth while pulling. Remove seals and springs, keeping them in order. Remove intermediate housing tubular dowel. Turn eccentric shaft so journal faces short axial direction. See Fig. 9 . Remove intermediate housing (without removing eccentric shaft), while pushing eccentric shaft upward.

Fig. 7: Locating Rotor Face Number
Fig.7
7. If seals stick to intermediate housing surface, remove and place in original position. Remove sealing rubbers. Remove front rotor side pieces, keeping them in order. Remove front rotor housing. Remove "O" ring from dowel hole.
8. Turn eccentric shaft so journal faces short axial direction. See Fig. 9 . Pull out eccentric shaft with front rotor. To remove front rotor, rock front rotor back and forth. Using Seal Remover (49-0813-225), remove outer oil seal from front rotor. See Fig. 10 . Remove remaining seals, springs and "O" ring.
9. Remove needle bearing retaining plate bolts from front housing. Remove needle bearing retaining plate, needle bearing, thrust washer and front stationary gear from front housing.

Fig. 8: Exploded View Of Internal Engine
Fig.8
Fig. 9: Removing Intermediate Housing
Fig.9
Fig. 10: Removing Oil Seal From Rotor
Fig.10

CLEANING

Housings
Clean sealing compound from surfaces with a cloth or brush soaked in solvent or thinner. Remove carbon on side surfaces of rotor chamber with extra-fine emery paper. DO NOT damage surface. Remove carbon from inner surface of rotor housings with cloth soaked in solvent or thinner. Remove deposits and rust from coolant passages on housings. Check rotor housings thoroughly for gas or water leakage.

Rotors
Remove carbon from rotor with sponge and carbon cleaning chemical. Use care not to damage soft material coating on side surfaces of rotor. Remove carbon from grooves. Wash rotor in cleaning solution. Clean carbon from seals and wash with cleaning solution. DO NOT use emery paper.

INSPECTION AND RECONDITIONING

Front, Intermediate and Rear Housings
1. Using a straightedge and feeler gauge, check housings for warpage. See Fig. 11 . If not within specifications, replace housing(s).
2. Using dial indicator and Mount (49-0727-570), check seal contact surface for wear by sliding indicator across surface. Check oil seal and side seal step wear from inside to outside of each seal tracking pattern. See Fig. 12 . Replace as necessary.

OIL SEAL STEP WEAR SPECIFICATIONS



Fig. 11: Checking Housing Distortion
Fig.11
Fig. 12: Checking Oil Seal and Side Seal Step Wear
Fig.12

Stationary Gears
1. Check front and rear stationary gear for cracked worn or chipped teeth. To replace front stationary gear, remove needle bearing retaining plate, needle bearing and thrust washer. To replace rear stationary gear, remove bolts, and drive gear out with a drift.
2. To install front stationary gear, reverse removal procedure. To install rear stationary gear, apply petroleum jelly to NEW "O" ring and place on rear stationary gear. Align stationary gear housing slot with housing dowel pin. Apply sealant to gear flange. Align slot with dowel and tap gear in place. Tighten bolts to specifications.

Eccentric Shaft and Main Bearings
1. Clean eccentric shaft in solvent. Apply compressed air to oil passages. Check oil jet for weak spring and stuck or damaged steel check ball. Place eccentric shaft in "V" blocks and check shaft runout. Maximum runout allowable is .0024" (.06 mm).

The main bearing oil clearance specification allows for a wider tolerance on outside ends of eccentric shaft main bearing journals. See Fig. 13 .

Fig. 13: Measuring Main Journal Taper
Fig.13

2. To find main bearing clearance, measure main bearing I.D. and eccentric shaft journal O.D. in at least 4 points of each bearing and journal. If not within specifications, replace main bearing and/or eccentric shaft. To replace main bearing, remove rear stationary gear as previously described. Remove screw retaining main bearing.
3. Press bearing from stationary gear. Bearing comes out on flange side. To install main bearing, press bearing in opposite direction of removal. Ensure NEW bearing lug aligns with slot on stationary gear.

Pilot Bearing
Inspect pilot bearing while installed in eccentric shaft. Check for wear or damage, and rotating condition. Replace as necessary. To replace pilot bearing, remove bearing and oil seal using Bearing Puller (49-1285-071). Install new bearing and oil seal using Bearing Installer (49-F011-1A1) and Handle (49-G030-797). Bearing outside diameter should be .79" (20 mm). Insertion depth should be .453-.482 (11.5-12.3 mm).

Rotor Housings
Check chromium-plated surface on housing for damage. Using a micrometer, measure rotor housing width at points "A", "B", "C" and "D". See Fig. 14 . Difference between "A" value and minimum value among "B", "C" and "D" is distortion. If distortion is not within specifications, replace housing.

Fig. 14: Checking Rotor Housing Width Distortion
Fig.14
Rotors
1. Visually inspect rotors. Replace if any visual defects are found. Check condition of internal gear. Check clearance between rotor and rotor housing. Measure maximum rotor width at 3 points of rotor (near each apex). See Fig. 15 . Clearance is difference between rotor housing value "A" (as previously described) and maximum width of rotor.

Fig. 15: Measuring Rotor-to-Side Housing Clearance
Fig.15
2. If clearance is greater or less than specification, replace rotor assembly. Check rotor corner seal bores for wear with Corner Seal Gauge (49-0839-165). See Fig. 16 . If neither end of gauge fits into rotor bores, use original corner seals. If both ends of gauge fit into bores, replace rotor. If one end of gauge does not fit and other end does, replace corner seals.

Fig. 16: Checking Corner Seal Bore Wear
Fig.16

Rotor Bearing
1. Inspect bearing for flaking and scoring. Check rotor bearing clearance. Measure I.D. of rotor bearing and O.D. of rotor bearing journal on eccentric shaft. If clearance exceeds specifications, replace rotor bearing.
2. To replace bearing, place rotor in press with internal gear downward. Using Rotor Bearing Replacer (49-0813-240) without adapter ring, press bearing from rotor. To install, reverse removal procedure. Press new bearing in from opposite side as removed. Ensure bearing lug is aligned with slot in rotor bore.

Rotor Oil Seals and Springs
Inspect oil seal for wear or damage and replace as necessary. Measure seal lip width. Maximum width is .020" (.5 mm). Install oil seal springs and oil seals on rotor. Measure seal protrusion. If protrusion is less than .020" (.5 mm), replace oil seal and/or springs. See Fig. 17 .

Fig. 17: Measuring Rotor Oil Seal
Fig.17

Apex Seal and Spring
1. Measure combined height of upper and lower apex seal at 2 points. See Fig. 18 . Combined standard height should be .33" (8.5 mm). If apex seal height is less than .256" (6.5 mm), replace both apex seals and apex seal springs.
2. To check apex seal warpage, put 2 apex seals together, top edge-to-top edge. Measure between top surfaces of apex seals with a feeler gauge. See Fig. 18 . Check all apex seals. If warpage exists in the middle of seals, replace apex seals. If end of seals are warped, seals can be reused.
3. Install apex seal in rotor in its original groove. Check clearance between apex seal and rotor groove with feeler gauge. See Fig. 19 . If not within specification, replace apex seal.
4. Check apex seal spring for wear and free height. See Fig. 20 . If free height is less than .138" (3.5 mm), replace long spring. Replace short apex seal spring only when replacing apex seals.

Fig. 18: Checking Apex Seal Height & Warpage
Fig.18
Fig. 19: Measuring Apex, Side and Corner Seal Clearance
Fig.19
Fig. 20: Checking Apex Seal Spring Free Height
Fig.20
Side Seal and Spring
1. With side seal and spring installed, press seal with finger and ensure it moves freely in groove. Check side seal protrusion. If not within specifications, replace side seal and/or spring. Side seal protrusion should be .020" (.5 mm).
2. Check clearance between side seal and groove with feeler gauge. If clearance exceeds specifications, replace side seal. Check clearance between side seals and corner seals. See Fig. 19 . If clearance exceeds specification, replace side seals.
3. When replacing side seals, adjust clearance between new side seal and corner seal by filing one end of side seal. Using a fine-cut file or sandpaper, shape cut unfinished end to match contour of corner seal. Adjust clearance to .002-.006" (.05-.15 mm).

Corner Seal, Soft Seal and Spring
Install corner spring and seal in rotor groove. Check free movement of seal by pressing with finger. Check corner seal protrusion from side surface of rotor. If corner seals protrude less than .020" (.5 mm), replace corner seals or springs.

Needle Bearing and Retaining Plate
Check needle bearing and retaining plate for wear or damage. Replace as necessary.

Oil Pump Drive Chain and Sprockets
Check oil pump drive chain for broken links. Check oil pump sprockets for cracks, wear or damaged teeth. Replace as necessary.


REASSEMBLY
Replace all rubber seals. Apply clean engine oil to all sliding and rotating parts.

Rotor Oil Seals
1. Place rotor on a soft surface. Install oil seal into rotor (without "O" ring). Ensure new oil seal moves smoothly in its groove. Remove oil seal from rotor. Properly install oil seal springs indicated by Cream or Blue paint. See Fig. 21 . Fit round edge of spring in stopper hole of groove.

Fig. 21: Installing Oil Seal Spring On Rotor
Fig.21
2. Install NEW "O" ring in oil seal. Place inner oil seal in groove with square edge of spring in oil seal notch. Using old oil seal, push new seal until lip of new seal is .016" (.41 mm) below rotor surface. See Fig. 22 . Carefully install remaining oil seal springs and oil seals without deforming oil seal lip. See Fig. 23 . Push each oil seal slowly by hand and confirm free movement of seal.

Fig. 22: Installing Oil Seal On Rotor
Fig.22
Fig. 23: Exploded View Of Rotor Seals
Fig.23
DO NOT apply engine oil to sealing rubber.

Front Housing
1. Mount front housing horizontally on engine stand or suitable bench. Position needle bearing retaining plate with chamfer facing front housing. Install needle bearing and plate. Tighten needle bearing retaining plate bolts to 12-16 ft. lbs. (16-22 N.m). Apply petroleum jelly to NEW outer and inner sealing rubbers. Install outer sealing rubber with White paint facing groove side wall. See Fig. 24 .
2. Install inner sealing rubber so Blue paint faces groove outer wall and seam is positioned properly. See Fig. 24 . Ensure sealing rubbers are NOT twisted. Apply engine oil to contact surfaces, stationary gear and main bearing.

Fig. 24: Positioning Sealing Rubber On Front Housing
Fig.24

Corner and Side Seals
1. Place front rotor on a soft surface (front side upward). Install side seal springs and seals on front side of rotor. Ensure painted surfaces face inward. Install side seals on rear side of rotor and apex seals after rotor is installed in housing.
2. Install corner seal springs, corner seals and soft seals on front of rotor. See Fig. 23 . Ensure corner seal chamfered surface faces inward. Ensure smooth movement of each corner and side seal by lightly pressing them. Apply petroleum jelly to side seals.

Front Rotor and Eccentric Shaft
1. Apply engine oil to rotor oil seal, rotor bearing and internal gear. Place front rotor on front housing so rotor internal gear and stationary gear mesh. Ensure one rotor apex points down. See Fig. 25 . DO NOT place rotor on sealing rubbers.
2. Apply engine oil to rotor bearing and eccentric shaft journal. Carefully insert eccentric shaft without damaging rotor or main bearings.

Fig. 25: Positioning Front Rotor For Assembly
Fig.25
Improperly installed apex seals may result in poor gas sealing performance.

Front Rotor Housing and Rotor Seals
1. Ensure corner seals are aligned with rotor apex grooves. Apply petroleum jelly to NEW "O" ring and install into tubular dowel hole. Apply sealant to front side of rotor housing. See Fig. 26 . Apply engine oil to inner surface of rotor housing. Install front rotor housing. Apply engine oil to tubular dowel and install dowel.

Fig. 26: Applying Sealant To Housing
Fig.26
2. If reusing old apex seals, remove old bonding agent from apex seal and side piece. Apply bonding agent to angled edge of side piece and assemble side piece and apex seal. Overall length of assembled side piece and seal must be 3.14" (79.8 mm). See Fig. 27 .
3. Assemble lower apex seal to apex seal and side piece. Insert seal assembly into rotor apex groove with side piece toward rear of rotor.
4. Install short and long apex seal springs. See Fig. 28 and Fig. 29 . Install NEW soft seal into corner seal. Install corner seal spring. Install corner seal with chamfered surface facing inward. Install side seal springs and seals with painted surface facing inward. Ensure free movement of each corner and apex seal assembly by pressing lightly.

Fig. 27: Checking Apex Seal Assembled Length
Fig.27
Fig. 28: Positioning Apex Seal Springs
Fig.28
Fig. 29: Installing Apex Seal Springs
Fig.29
Intermediate Housing
1. Apply petroleum jelly to NEW outer and inner sealing rubbers. Install outer sealing rubber with White paint facing side wall of groove. See Fig. 30 . Install inner sealing rubber to front side with Blue paint area facing outer wall of groove and position seam properly. See Fig. 30 .
2. Ensure sealing rubbers are not twisted. DO NOT apply engine oil to sealing rubbers. Apply engine oil to housing contact surfaces and rotor oil seal. Apply petroleum jelly to NEW "O" ring and install. Apply sealant to housing. See Fig. 27 .
3. Ensure side pieces of apex seals are in position. Turn eccentric shaft so journal faces short axial direction. See Fig. 9 . Lift eccentric shaft about 1.2" (30.5 mm) and install intermediate housing.
4. Install outer and inner sealing rubbers to rear side of intermediate housing using same method as in step 1). Apply engine oil to contact surfaces. DO NOT apply engine oil to sealing rubbers.

Fig. 30: Positioning Sealing Rubber On Intermediate Housing
Fig.30
Rear Rotor, Seals and Housing
Position rear rotor. See Fig. 31 . To complete installation, 0use procedure described to install front rotor and housing.

Fig. 31: Positioning Rear Rotor For Assembly
Fig.31
The side piece of rotor seal must be toward rear of rotor.

Rear Housing
1. Apply engine oil to NEW rear oil seal and groove of rear stationary gear. Install oil seal into rear stationary gear. Install oil regulator valve and tighten to 51-58 ft. lbs. (69-78 N.m).
2. Apply petroleum jelly to NEW outer and inner sealing rubbers. Install outer sealing rubber with White paint facing side wall in groove. Install inner sealing rubber with Blue paint facing outer wall in groove. Ensure sealing rubbers are NOT twisted. Align seams to proper position. See Fig. 30 .
3. Apply oil to contact surfaces, stationary gear and main bearing. DO NOT apply oil to sealing rubbers. Coat rear rotor oil seal with oil. Apply petroleum jelly to NEW "O" ring and install in rear rotor housing. Apply sealant to lower outside edges of rear rotor housing.
4. Install rear housing on rear rotor housing. Ensure pieces of front and rear apex seals DO NOT wedge between rotor housing and rear housing.

The tension bolt marked "M" on bolt head is for No. 17 position and bolt with protector tube is for No. 18 position. See Fig. 32 .

5. Apply engine oil to NEW seal washers and housing bolt threads. Install tension bolts and tighten gradually in sequence to specification. See Fig. 32 . Turn eccentric shaft to ensure rotation is easy and smooth.

Fig. 32: Tension Bolt Tightening Sequence
Fig.32

Flywheel/Counterweight
Apply engine oil to rear housing seal. Insert Woodruff key in eccentric shaft. On MT models, install flywheel. On AT models, install counterweight. On all models, apply thread locking compound to eccentric shaft threads. Apply sealant to large nut contact surface. Install and tighten large nut to 290-360 ft. lbs. (393-490 N.m).

Front Balance Weight, Bearing and Spacer
1. Install spacer, needle bearing, thrust washer, balance weight, oil pump sprocket and drive gear. See Fig. 5 . Ensure needle bearing is NOT wedged by spacer. Install eccentric shaft pulley hub and lock bolt. Tighten bolt to specification.
2. Measure end play of eccentric shaft with dial indicator attached to either flywheel/counterweight or eccentric shaft pulley. If not within specifications, replace spacer with a thicker or thinner spacer. With end play within specification, remove lock bolt, pulley, drive gear and oil pump drive sprocket.

Front Cover
1. Apply engine oil to oil pump shaft and install oil pump. Install Woodruff key on eccentric shaft. Install oil pump drive gear, oil pump sprocket and chain as an assembly.
2. Install NEW washer and oil pump lock nut. Bend washer to lock nut. Install drive gear with chamfered surface toward front housing. Apply engine oil to NEW front cover oil seal and install seal into front cover. Install oil control valve in front cover and tighten to specification.
3. Apply petroleum jelly to NEW "O" ring and install on front cover with NEW front cover gasket. Install front cover and tighten to specification. Install eccentric shaft pulley hub. Install eccentric shaft lock bolt and tighten by hand. Remove lock bolt and measure pulley hub protrusion. See Fig. 33 . If protrusion exceeds .0961" (2.44 mm), needle bearing may be wedged by spacer. Remove and reposition needle bearing if necessary.

Fig. 33: Checking Pulley Hub Protrusion
Fig.33

4. Apply thread locking compound to NEW eccentric shaft lock bolt threads and sealant to flange face of bolt. Install spring, by-pass valve, NEW "O" ring and lock bolt into eccentric shaft. Install oil strainer and new gasket. Tighten to specification.

Oil Pan
If installing oil pan without a gasket, apply a .16-.24" (4-6 mm) diameter bead of silicone sealant to engine housing. Sealant must be continuously rimmed inside of bolt thread holes and ends should overlap. If installing oil pan with gasket, apply a .16-.24" (4-6 mm) diameter bead of silicone sealant to both sides of gasket. Install oil pan and tighten to specification. To complete reassembly, reverse disassembly procedure.

External Components
1. To reassemble external components, reverse disassembly procedure. Install White painted oil tube to oil nozzle in front rotor housing and Yellow painted oil tube into oil nozzle in rear rotor housing. Ensure notch on mixing plate aligns with notch in mating hole in intermediate housing.
2. Ensure oil tubes are connected to metering oil pump as shown. See Fig. 34 . Install exhaust manifold gaskets with crimped side facing exhaust manifold. When installing turbocharger, tighten bolts in sequence to specification. See Fig. 4 .

Fig. 34: Engine Oiling Circuit Diagram
Fig.34


ENGINE OILING


ENGINE LUBRICATION SYSTEM

Crankcase Capacity
Dry Fill crankcase capacity is 5.2 qts. (4.9L). Oil change W/filter replacement capacity is 4.0 qts. (3.8L).

Oil Pressure
With engine warm and at 3000 RPM, oil pressure should be 50 psi (3.5 kg/cm2) minimum.

Engine oil pump is mounted behind front cover. See Fig. 5.

OIL PUMP DISASSEMBLY AND REASSEMBLY
With oil pump removed, remove snap ring from rear of shaft. Remove rotors and plates. Remove lock screw and remove shaft. See Fig. 35 . To reassemble, reverse disassembly procedure. Ensure match marks on outer rotor and inner rotors face front housing.

Fig. 35: Exploded View Of Oil Pump
Fig.35

Inspection
If oil pump is not within specifications, replace components as necessary.

OIL PUMP SPECIFICATIONS

METERING OIL PUMP

Removal
Drain engine oil. Disconnect electrical connectors. Disconnect oil tubes and note location for reassembly. Remove mounting bolts and pump from front housing. Remove "O" ring.

Inspection
Metering oil pump is controlled by Engine Control Module (ECM) and may set Diagnostic Trouble Codes (DTCs) 20, 26, 27 and 37 if pump or wiring are malfunctioning.

Installation
Coat NEW "O" ring with engine oil and replace oil tube gasket. Install pump and tighten mounting bolts to 70-95 INCH lbs. (7.9-10.7 N.m). To complete installation, reverse removal procedure.


ENGINE SPECIFICATIONS

ENGINE SPECIFICATIONS

ROTOR HOUSING, INTERMEDIATE HOUSING AND ROTOR SPECIFICATIONS

APEX SEAL SPECIFICATIONS

SIDE SEAL SPECIFICATIONS

ECCENTRIC SHAFT MAIN AND ROTOR BEARINGS SPECIFICATIONS

CORNER SEAL SPECIFICATIONS


TORQUE SPECIFICATIONS





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Mazda RX-7 1993-1995 FD3S

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