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A - ENGINE/VIN ID Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:41PM ARTICLE BEGINNING 1983-88 ENGINE PERFORMANCE Mazda VIN Code Identification RX7 MODEL IDENTIFICATION Fig. 1: VIN Code Identification VIN CODE ID EXPLANATION Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label in Fig. 1. The legend listed below will also be found in Fig. 1.
1 * Constant For All Models 10 Vehicle Model Year D * 1983 E * 1984 F * 1985 G * 1986 H * 1987 J * 1988 11 Assembly Plant 0 * Hiroshima, Japan 12-17 Serial Number * Sequential Production Number END OF ARTICLE A - ENGINE/VIN ID Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.
AIR INJECTION SYSTEM - CARBURETED Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:42PM ARTICLE BEGINNING 1984 Exhaust Emission Systems CARBURETED MODELS AIR INJECTION SYSTEM DESCRIPTION This system controls CO, HC and NOx emissions by injecting secondary air into the exhaust system to cause further burning of exhaust gases.
1) With engine at normal operating temperature, inspect all hose connections for leaks. Check for pump noise and belt tension. 2) Stop engine and disconnect air line at air control valve. Connect hose to a pressure gauge. Connect tachometer to engine. 3) Start engine and run at idle speed. Gauge should register more than 1.64 psi (.12 kg/cmý) with engine at 800 RPM. If pump pressure is below specification, replace air pump.
Fig. 2: Testing Relief Solenoid Valve RELIEF SOLENOID VALVE SIGNAL CHECK 1) Warm engine to normal operating temperature. Connect tachometer to engine. Disconnect connector from throttle sensor and connect a jumper wire between terminals "A" and "C" of connector. See Fig. 3. 2) Disconnect the vacuum sensing tube (from relief solenoid valve to pipe) at the pipe. Place a finger over the vacuum sensing tube opening. Start engine. Air should be sucked into the tube. 3) Increase engine speed.
valve and vacuum pipe. Blow through switching valve from vacuum sensing tube "B". See Fig. 2. Air should pass through valve and escape from port "C". 2) Disconnect electrical connector from switching solenoid valve and connect battery power to terminals on valve. Blow through hose again. Air should pass through valve and escape through port "A" of the valve. If valve does not respond as described, replace switching solenoid valve.
diaphragm shaft. Before installing air horn, make necessary float adjustments. ADJUSTMENT SPECIFICATIONS CARBURETOR ADJUSTMENT SPECIFICATIONS ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Specification RX7 Float Level In. (mm) ......................... .61-.65 (15.5-16.5) Float Drop In. (mm) ........................ 1.98-2.02 (50.5-51.5) Choke Linkage In. (mm) ....................... .040-.047 (1.0-1.2) Accel. Cable Free Play In. (mm) ................ .04-.12 (1.
Fig. 4: Testing Choke Switch and Choke Magnet CHOKE RELAY Disconnect the connector from the relay. Check the continuity between the numbered terminals using an ohmmeter. With battery voltage applied between terminals 6 (positive) and 5 (negative), there should be continuity between 3 and 4 and no continuity between 1 and 2. With no power applied, there should be continuity between 1 and 2 and no continuity between 3 and 4. Fig.
Fig. 6: Testing Heat Hazard Sensor PORT AIR SOLENOID VALVE 1) Warm up engine and run at idle speed. Connect a tachometer to engine. Disconnect the connector from the throttle sensor and connect a jumper wire to "A" and "C" terminals of the connector. See Fig. 3. Connect a voltmeter to the port air solenoid terminal and ground. 2) Increase engine speed and watch voltmeter. With engine speed below 3000 RPM, voltage should be below 2 volts.
AIR INJECTION SYSTEM - EFI Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:42PM ARTICLE BEGINNING 1984 EXHAUST EMISSION SYSTEM Mazda Air Management Systems - Fuel Injected Models RX7 DESCRIPTION The air management system consists of the following subsystems: Air Injection, Secondary Air Control, Air Induction and ByPass Air Control.
when the overdrive switch is open. Switching Solenoid Valve Switches secondary air to exhaust port or rear catalyst. Vacuum Control Solenoid Valve Cuts out vacuum to distributor during deceleration. SENSORS Heat Hazard Sensor Detects floor temperature and sends signal to relief solenoid valve control unit. Intake Air Temperature Sensor Detects intake air temperature and controls pressure control valve and BAC valve through control unit.
Air Pump 1) With engine at normal operating temperature, inspect all hose connections for leaks. Check for pump noise and belt tension. 2) Stop engine and disconnect air line at air control valve. Connect hose to a pressure gauge. Connect tachometer to engine. See Fig. 2. 3) Start engine and run at idle speed. Gauge should register more than 1.64 psi (.12 kg/cmý) with engine at 800 RPM. If pump pressure is below specification, replace air pump. Fig.
should flow out from the air hose. Reconnect the vacuum sensing tube and the air hose. 4) Disconnect the split air hose (from check valve to intake manifold) at the intake manifold. Place a finger over the port opening. Disconnect the vacuum sensing tube (from switching solenoid to pipe) at the pipe. 5) Air should flow out from the port. Reconnect the vacuum sensing tube and split air hose. If air control valve does not respond as described, replace air control valve.
make sure air is sucked into the tube. Gradually increase the engine speed and make sure that air is not sucked into the tube when engine RPM is 1000-2000 RPM or more. 3) Disconnect the connector from the number 1 water temperature switch and connect a jumper wire to both terminals of the connector. Pull the choke knob out about .6" (15 mm). Increase the engine speed and make sure that air is sucked into the tube at any engine speed.
1) Disconnect intake tube from vent solenoid and remove connector. Blow through vent solenoid valve from intake tube and make sure that air does not pass. 2) Apply power to vent solenoid terminals. See Fig. 6. Blow through vent solenoid valve from intake tube and make sure that air passes. If vent solenoid does not pass air, replace unit. Fig. 6: Vent Solenoid Valve Vacuum Solenoid Valve 1) Disconnect vacuum hose from solenoid valve. Remove vacuum solenoid valve connector.
Fig. 8: Testing Air Supply Valve Adjusting Air Supply Valve 1) Warm up engine and run at idling speed. Connect a tachometer to engine. Disconnect vent and vacuum solenoid valve connector. 2) Disconnect vent and vacuum solenoid valve connector. Check idling speed and adjust, if necessary. Disconnect air supply valve connector and apply electrical power to air supply. 3) Make sure engine speed is within 1000-1700 RPM.
transmission is in neutral, switch should be closed. When transmission is in gear, switch should be open. See Fig. 10. Fig. 10: Testing Neutral Switch AIR INDUCTION SYSTEM Throttle Chamber 1) The No. 1 secondary throttle valve starts to open when the primary valve opens 15ø and completely opens at the same time when the primary valve fully opens. 2) Check the clearance between the primary throttle valve and the wall of the throttle bore when the No. 1 secondary valve starts to open.
Fig. 12: Checking Fast Idle Cam 3) When the connect matching mark aligns with the center of the cam roller, clearance (throttle chamber to primary throttle valve) should be .016-.02" (.4-.5 mm). If clearance is off, turn the fast idling adjusting screw to bring into specifications. Accelerator Linkage Remove the air funnel and, with the accelerator pedal fully depressed, observe the position of the throttle valves. They should be horizontal (wide open position).
Fig. 14: Checking Double Throttle Diaphragm Delay Valve 1) Disconnect vacuum delay valve. Connect approx. 3.5 Ft. of vacuum tube to the vacuum pump tester. Completely shut the other side of the vacuum delay valve with your thumb. 2) Apply a vacuum of over 19.7 in. Hg by using the vacuum pump tester. Release your thumb from vacuum delay valve and check time required for vacuum reading to decrease to 3.9 in. Hg from 15.7 in. Hg in approx. 13 seconds.
CARBURETOR - NIKKI 4-BBL Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:43PM ARTICLE BEGINNING 1984 Nikki Carburetors NIKKI 4-BARREL Mazda RX7 DESCRIPTION Carburetor is of 4-barrel, 2-stage design. Primary stage includes idle system, slow speed circuit, accelerator pump system and main metering system. In addition, Federal models are equipped with a sub-zero starting device which admits fluid into the primary stage.
Fig. 2: Float Drop Adjustment CHOKE LINKAGE (FAST IDLE OPENING ANGLE) Close choke valve fully and measure clearance between primary throttle valve and wall of throttle bore. Set clearance to .040-.047" (1.0-1.2 mm) by bending fast idle rod. See Fig. 3. Fig. 3: Choke Linkage (Fast Idle Opening Angle) Bend fast idle rod to adjust. CHOKE VALVE OPENING ANGLE NOTE: Choke diaphragm No. 1 is the dual diaphragm assembly, choke diaphragm No. 2 is the single diaphragm assembly.
Fig. 4: Choke Valve Opening Angle Adjustment NO. 2 CHOKE DIAPHRAGM 1) Disconnect vacuum sensing tube from No. 2 vacuum diaphragm. Pull choke lever link out fully and hold in place. Choke valve should close fully. (Cool bi-metallic coil if necessary). 2) Apply more than 19.7 in. Hg to vacuum diaphragm and measure clearance between choke valve and wall of air horn. Clearance should be .057-.070" (1.46-1.80 mm). CHOKE DIAPHRAGM OPERATION (NO. 1 & NO. 2 DIAPHRAGMS) Remove air cleaner.
Fig. 5: Checking Automatic Choke Release CHECKING CARBURETOR HEATER 1) Disconnect electrical connector from No. 1 water temperature switch and connect jumper wire to both terminals of connector. Connect tachometer to engine. 2) Disconnect carburetor heater electrical connector and connect voltmeter to connector. Start engine and set engine speed at 2000 RPM with choke knob. 3) With choke knob pulled out, current should flow to carburetor heater lead.
1) Disconnect connector from relay. Using an ohmmeter without power applied, connect leads between terminals 1 and 2. There should be continuity between terminals 1 and 2, but not between 3 and 4. 2) Connect battery power to terminal 6 and ground terminal 5. Continuity should now exist between terminals 3 and 4, but not at terminals 1 and 2. Fig. 7: Checking Choke Relay Continuity Continuity should exist at terminals 1 and 2 without power applied; at terminals 3 and 4 with power applied.
Fig. 9: Checking Hot Assist Relay There should be no continuity between terminals 1 and 4 with power applied; continuity should exist without power. THROTTLE OPENER A/C Models Only 1) Turn off all accessories. Remove fuel filler cap. Disconnect and plug idle compensator tube at air cleaner. Connect tachometer to engine and warm engine to normal operating temperature. 2) Disconnect electrical connector from air switching solenoid valve (Gray color).
2) If idle speed did not drop, remove compensator valve and blow through valve from both ports. Air should pass through compensator valve. If not replace altitude compensator valve. Fig. 11: Adjusting Accelerator Cable and Pedal Height ACCELERATOR CABLE ADJUSTMENT 1) Check accelerator pedal position. Pedal should be 1.5-1.9" (37-47 mm) lower than brake pedal. See Fig. 11. If necessary, adjust nut "A" to obtain correct position. 2) Cable free play at carburetor should be .04-.12" (1-3 mm).
5) From main body, remove accelerator pump rod, secondary throttle valve rod, throttle sensor and main body attaching bolts. Remove main body from throttle body. Fig. 12: Removing Jets and Air Bleeds 6) Remove secondary throttle attaching screws, cover, return spring, pin and clip, diaphragm, housing and gasket. Remove "E" clip, washer and shaft, accelerator pump lever, attaching screws, cover, diaphragm and return spring.
CHOKE RETURN & HOT START ASSIST SYSTEM Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:45PM ARTICLE BEGINNING 1984 Exhaust Emission Systems MAZDA RX7 CHOKE RETURN & HOT START ASSIST SYSTEMS DESCRIPTION The Choke Return system prevents the choke knob from being left unreturned to prevent overheating of the exhaust system.
CHOKE MAGNET Disconnect electrical connector from choke switch. Using an ohmmeter, check continuity between terminals. Continuity should exist between terminals number 6 and number 8. See Fig. 2. Fig. 2: Choke Switch Terminal Numbering HOT START ASSIST SYSTEM 1) Inspect hot start assist cable and linkage for proper installation, no binding or sticking, and full return. Warm engine to normal operating temperature and stop engine. 2) Disconnect leading and trailing primary wires from ignition coils.
DECELERATION CONTROL SYSTEM - CARBURETED Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:45PM ARTICLE BEGINNING 1984 Exhaust Emission Systems MAZDA RX7 CARBURETED MODELS DECELERATION CONTROL SYSTEM DESCRIPTION The deceleration system is designed to maintain a balanced air/fuel mixture during deceleration.
Fig. 1: Deceleration Control System THROTTLE SENSOR 1) Warm engine to normal operating temperature. Stop engine and connect tachometer. Disconnect Brown connector under air cleaner on carbon canister side of engine. 2) Using 2 voltmeters, connect negative lead of each voltmeter to each terminal in connector. Connect positive leads to "B" terminal of alternator. See Fig. 2. DECELERATION CONTROL SYSTEM - CARBURETED Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.co Fig.
earlier and turning screwing counterclockwise causes current to flow later. See Fig. 3. Fig. 3: Throttle Sensor Adjusting Screw Location 4) After adjustment, install cap over throttle sensor adjusting screw. Remove voltmeters and reconnect Brown connector. Remove tachometer. SHUTTER SOLENOID VALVE 1) Disconnect vacuum sensing tubes from shutter solenoid valve (Yellow color dot). Blow through solenoid valve through vacuum hose "B" shown in Fig. 4;.
DASHPOT (MAN. TRANS. ONLY) 1) Remove air cleaner. Check that dashpot rod does not bind throttle lever movement. Quickly operate throttle lever fully and make sure dashpot rod extends quickly. 2) Release throttle lever and make sure that throttle lever returns slowly to idle position after it has touched dashpot rod. Connect tachometer to engine. Start engine and warm to operating temperature. 3) Ensure engine idle speed is adjusted to specification. Operate throttle lever until it is away from dashpot rod.
DECELERATION CONTROL SYSTEM - EFI Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:46PM ARTICLE BEGINNING 1984 Exhaust Emission Systems MAZDA RX7 FUEL INJECTED MODELS DECELERATION CONTROL SYSTEM DESCRIPTION The deceleration system is designed to maintain a balanced air/fuel mixture during deceleration. This helps prevent backfiring. System consists of a fuel cut operation, throttle sensor, antiafterburn valve, and dashpot.
DECELERATION CONTROL SYSTEM - EFI Article Text (p. 2)1984 Mazda RX7For iluvmyrx7.com Fig. 1: Deceleration Control System THROTTLE SENSOR TEST 1) To check and adjust throttle sensor, proceed as follows. Warm up engine then turn it off. Connect voltmeters to checking connector (Green) as shown in Fig. 2. 2) Turn ignition switch on and check to see if current flows to one of the voltmeters.
Fig. 2: Voltmeters Connected to Adjust Throttle Sensor 4) Disconnect connector for throttle sensor. Connect an ohmmeter to throttle sensor as shown in Fig. 3. Open throttle valve and observe ohmmeter reading. At idle reading should be about 1000 ohms. Wide open reading should be about 5000 ohms. Fig. 3: Throttle Sensor Ohmmeter Connection ANTI-AFTERBURN VALVE TEST 1) Warm up engine and run it at idling speed. Disconnect air hose (air control valve-to-air pump) at air pump.
EMISSION APPLICATION Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:46PM ARTICLE BEGINNING 1984 ENGINE EMISSIONS Mazda Emission Control Applications 626, GLC, Pickup, RX7 EMISSION CONTROL DEVICE APPLICATIONS EMISSION CONTROL DEVICE APPLICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ B2000 2.0L PCV, AIS, EVAP, OC, EGR, AAV (1), ECC, DCS, HIC, ITCS, PAS (2), TOCS B2000 2.
MCS .................................... Mixture Control System OC ........................................ Oxyidation Catalyst O2 .............................................. Oxygen Sensor PAS .......................................... Pulse Air System PCV ............................ Positive Crankcase Ventilation SPK ..................................................... Spark TAC .................................. Thermostatic Air Cleaner TOCS ............................. Throttle Opener Cont.
FUEL EVAPORATION SYSTEM Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:46PM ARTICLE BEGINNING 1984 Fuel Evaporation Systems MAZDA ROTARY ENGINE RX7 DESCRIPTION System prevents escape of fuel vapors into atmosphere.
TESTING EVAPORATION LINE From canister, remove evaporation hose leading to fuel tank. Connect "U" tube pressure gauge to evaporation hose. NOTE: Evaporation line test is the same as on piston engines. To complete testing procedure, see "TESTING, Evaporation Line" in "Mazda Piston Engine" article in this section. CHECK & CUT VALVE NOTE: Check and cut valve test is the same as on piston engines. See "TESTING, Check and Cut Valve" in "Mazda Piston Engine" article in this section. Fig.
FUEL INJECTION SYSTEM Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:47PM ARTICLE BEGINNING 1984-85 Fuel Injection MAZDA RX7 DESCRIPTION The electronically controlled fuel injection system precisely meters the amount of fuel injected in each rotor. The Electronic Control Unit (ECU) is the "brain" of the system.
Fig. 2: Disconnecting Vacuum Hose from Fuel Pressure Regulator Control Valve PRESSURE REGULATOR FUEL PRESSURE 1) Disconnect negative battery terminal. Using a shop rag wrapped around main fuel hose, disconnect main fuel hose from fuel line. Using 3-way connector, connect pressure gauge to main fuel line. 2) Reconnect negative battery terminal. Start engine. Disconnect vacuum hose between pressure regulator and pressure regulator control valve at control valve. See Fig. 2.
FUEL INJECTION SYSTEM Article Text (p. 3)1984 Mazda RX7For iluvmyrx7.com Fig.
INJECTOR OPERATION 1) Using a mechanic's stethoscope, listen to each injector for normal "clicking" operating noise at idle and under acceleration. 2) If both injectors do not operate, ensure that there is continuity in wire between trailing coil and terminal "U" of ECU connector. If there is continuity, check main fusible link located next to left strut tower. 3) If okay, turn ignition on and ensure that main relays (2) click each time key is turned on.
PULSATION DAMPER TEST Start engine and run at idle. Place finger over pulsation damper and ensure damper pulsates. If not, replace pulsation damper. ATMOSPHERIC PRESSURE SENSOR TEST Turn ignition on. Using a voltmeter connected to the atmospheric pressure sensor terminal "D", measure voltage. See Fig. 5. Voltage should be 3.5-4.5 volts at sea level, or 2.5-3.5 volts above an altitude of 6500 ft. (2000 m). Fig.
INTAKE AIR TEMPERATURE SENSOR RESISTANCE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Temperature Ohms 68øF (20øC) ................. 45,650-37,350 122øF (50øC) ................ 13,040-10,660 185øF (85øC) .................... 3850-3150 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ THROTTLE SENSOR TEST For complete throttle sensor testing procedures, see the ROTARY TUNE-UP article in the TUNE-UP section. COOLANT TEMPERATURE SWITCH TEST Coolant temperature switch is located in radiator.
Fig. 7: Checking Airflow Meter Resistance AIRFLOW MEASURING PLATE TEST Using a screwdriver, depress measuring plate fully and measure resistance between terminals on airflow meter connector. See AIRFLOW MEASURING PLATE RESISTANCE table for resistance values. AIRFLOW MEASURING PLATE RESISTANCE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Terminals E1 to FC Plate Fully Plate Fully E2 to VS Plate Fully Plate Fully Ohms Closed ........ No Continuity Open ...................... 0 Closed ...............
1) Remove storage compartment located behind driver's seat. Disconnect fuel pump connector and raise vehicle on hoist. 2) Remove pump bracket clamp bolt. Disconnect and plug inlet and outlet hoses. Remove fuel pump from bracket. INSTALLATION To install, reverse removal procedure. Check for fuel leakage. IDLE SPEED ADJUSTMENT For complete adjustment procedures, see the ROTARY TUNE-UP article in the TUNE-UP section. END OF ARTICLE FUEL INJECTION SYSTEM Article Text (p. 81984 Mazda RX7For iluvmyrx7.
FUEL PUMP - ELECTRIC Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:48PM ARTICLE BEGINNING 1984 Electric Fuel Pump MAZDA RX7, PICKUP DESCRIPTION & OPERATION Pulsating electric fuel pump is mounted near fuel tank on frame member. Power is supplied when ignition switch is in "RUN" position. This circuit is protected by a 15 amp fuse (20 amp on RX7) at fuse panel.
fuel main hose from fuel pipe. Connect a pressure gauge. NOTE: Cover the hose with waste cloth since fuel is splashed out when disconnecting the hose. 2) Reconnect battery negative terminal. After turning ignition switch to "ON" position, short-circuit fuel pump short circuit terminal to start pump. See Fig. 3. Measure fuel pressure. Outlet pressure should be 49.8-71.1 psi (3.5-5 kg/cmý). Fig.
Removal & Installation (RX7) Remove rear floor mat and disconnect fuel pump electrical lead. Raise and support vehicle. Remove fuel pump cover. Disconnect inlet and outlet hoses from pump. Remove fuel pump. To install, reverse removal procedure. PRESSURE REGULATOR Removal & Installation 1) Remove intake manifold. Disconnect vacuum hose and fuel return hose. NOTE: Cover starter motor with waste cloth to absorb any fuel splashed on it.
IGNITION CONTROL SYSTEM - CARBURETED Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:49PM ARTICLE BEGINNING 1984 Exhaust Emission Systems MAZDA RX7 CARBURETED MODELS IGNITION CONTROL SYSTEM DESCRIPTION The Ignition Control system is used to regulate vacuum advance of leading and trailing distributor systems.
Leading Vacuum Control Solenoid Valve Signal 1) Warm up engine to normal operating temperature. Connect a tachometer to engine. Disconnect the vacuum sensing tube (from leading vacuum advance diaphragm to pipe) at the pipe. Place a finger over the pipe opening and make sure that air is not sucked into the pipe. 2) Gradually increase the engine speed and make sure that air is sucked into the pipe when the engine speed is 1000-2000 RPM or more.
Fig. 2: Testing Leading Vacuum Control Solenoid Valve Trailing Valve 1) Disconnect the vacuum solenoid sensing tubes from the solenoid valve and vacuum pipe. Blow through the solenoid valve from the vacuum sensing tube "B". Make sure the air passes through the valve and comes out the air filter "C". 2) Disconnect the connector from the trailing vacuum control valve and connect battery power to terminals on the valve. Blow through the valve from the vacuum sensing tube "B".
IGNITION CONTROL SYSTEM - EFI Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:49PM ARTICLE BEGINNING 1984 Exhaust Emission Systems MAZDA RX7 FUEL INJECTED MODELS IGNITION CONTROL SYSTEM DESCRIPTION The Ignition Control system is used to regulate vacuum advance of leading and trailing distributor systems. In addition, this system helps reduce CO and HC emissions by aiding pellet converter warm-up during cold engine starts.
Fig. 2: Checking for Signal 2) Gradually increase engine speed and make sure air is sucked into pipe when engine speed is 1000-1200 RPM or more. Decrease the engine speed from 4000 RPM rapidly and make sure air is not sucked into pipe while decelerating. Turn A/C switch on and make sure air is sucked into pipe at idling speed. Testing for Faulty Valve 1) Disconnect vacuum sensing tubes from solenoid valve and vacuum pipe. Blow through solenoid valve from port "B".
IGNITION SYSTEM Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:50PM ARTICLE BEGINNING 1984 Distributors & Ignition Systems MITSUBISHI ELECTRONIC IGNITION - MAZDA ROTARY ENGINE Mazda RX7 DESCRIPTION The Mitsubishi electronic ignition system, used on the Mazda RX7 rotary engine, is unique in that it has 2 sets of spark plugs (leading and trailing).
efficient combustion while reducing HC and CO emissions. As the primary circuit is broken in the leading and trailing ignition coils, a voltage surge occurs in the secondary circuit of the ignition coils. This high voltage is transmitted through the leading and trailing high tension wires to the distributor, rotor and spark plugs. An emission control unit is also included in the ignition control system, along with different sensing switches to provide proper timing under varying engine operating conditions.
Fig. 3: Adjusting Ignition Timing Distributor position determines leading timing. Vacuum unit position adjusts trailing timing. TESTING HIGH TENSION WIRE RESISTANCE CHECK Turn ignition switch "OFF". Connect ohmmeter leads to each end of coil-to-distributor high tension wire. Resistance should not exceed 16,000 ohms (plus or minus 400 ohms) per 39.37" (1 m). IGNITION COIL RESISTANCE CHECK Set an ohmmeter in the low scale.
C) for each set of pick-up coils. If not, replace pick-up coil and bearing assembly. PICK-UP COIL OPERATION CHECK 1) With distributor connector still disconnected, touch ammeter leads to leading terminals and then to trailing terminals. 2) Place a screwdriver against core of pick-up coil being tested. Indicator of meter should move each time screwdriver is taken quickly away from core. If not, replace pick-up coil and bearing assembly. IGNITOR CHECK 1) Remove ignitor from distributor base.
drive shaft through top of distributor housing. REASSEMBLY 1) Inspect distributor cap and rotor for cracks, carbon tracks, and burned or corroded terminals. 2) Assemble distributor in reverse order of disassembly, noting the following: Install reluctor shaft onto distributor drive shaft, engaging slots of reluctor shaft and governor pins. Install pick-up coil and coil base bearing assembly and tighten attaching screws. Install reluctor on shaft, driving spring pin in with a punch. Fig.
MIXTURE CONTROL SYSTEM - CARBURETED MODELS Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:51PM ARTICLE BEGINNING 1984 Exhaust Emission Systems MAZDA RX7 CARBURETED MODELS MIXTURE CONTROL SYSTEM RX7 DESCRIPTION Mixture control system controls air/fuel mixture ratio to maintain optimum emission levels under a variety of operating conditions.
Fig. 2: Checking Signal for Main Air Bleed Control Solenoid Valve RICHER SOLENOID VALVE SIGNAL 1) Start the engine and run at idle speed. Connect a voltmeter to the richer solenoid valve terminal and ground, and take reading. Voltage should be 12 volts. Increase the engine speed more than 1500 RPM and then decrease it. 2) Voltmeter should show below 2 volts for 30 seconds when the engine speed becomes 1100 RPM or less.
PCV SYSTEM Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:52PM ARTICLE BEGINNING 1984 Crankcase Ventilation MAZDA B2000, B2200, GLC, RX7 & 626 DESCRIPTION & OPERATION PISTON ENGINE MODELS Gasoline The PCV system includes 2 hoses and a PCV valve. Crankcase vapors are normally drawn from valve cover through PCV valve and into intake manifold. A hose from the air cleaner to the valve cover supplies fresh air to the crankcase.
Fig. 2: B2200 Diesel Pickup Crankcase Ventilation System TESTING PISTON ENGINE MODELS GLC Remove PCV valve. Blow through valve with mouth pressure from valve cover side of valve. Air should pass through. Blow through valve from opposite end. Air should not pass through. If valve does not operate as described, replace valve. 626 With engine idling at normal operating temperature, remove PCV valve from valve cover. Close off valve opening with finger and check that idle speed drops.
the PCV valve inlet. If idle speed does not drop, replace PCV valve. NOTE: To replace PCV valve on California models with automatic transmissions and on all Federal models, first remove carburetor. Carburetor removal is not necessary on other B2000 models. ROTARY ENGINE MODELS 1) Disconnect purge valve-to-oil filler tube hose from purge valve. Start engine and run at idle speed. Place finger over open purge valve port and feel that no vacuum is present. See Fig. 4.
VACUUM DIAGRAMS Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:52PM ARTICLE BEGINNING 1984 Exhaust Emission Systems MAZDA RX7 VACUUM DIAGRAMS Fig.
For iluvmyrx7.com VACUUM DIAGRAMS Article 2)1984 Mazda Fig. 2: Vacuum Diagram ForText Fuel(p.
TUNE-UP - ROTARY Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:52PM ARTICLE BEGINNING 1984 Mazda Rotary Tune-Up TUNE-UP RX7 IDENTIFICATION ENGINE IDENTIFICATION The RX7 will have one of two engines, a carbureted model and a EGI (Electronic Gasoline Injection) model, regulated by a computer. The engine code for both models is stamped on the rear rotor housing, to the rear of the oil filter.
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ HIGH TENSION WIRE RESISTANCE Carefully remove high tension wires from spark plugs and distributor cap. Using an ohmmeter, measure resistance of wires while gently twisting wires. If resistance is not to specifications, or fluctuates from infinity to any value, replace high tension wire(s). HIGH TENSION WIRE RESISTANCE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application All Models Ohms ..................
Fig. 2: Connecting Timing Light Check leading plug timing first. Fig. 3: Ignition Timing Mark Location IGNITION TIMING (ATDC @ 800 RPM) ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Timing Leading Carbureted Models ............................................. 0ø Fuel Injected Models .......................................... 5ø Trailing Carbureted Models ............................................ 20ø Fuel Injected Models ........................................
Fuel Injected Models 1) Turn off all accessories. Connect a tachometer to engine. Ensure parking brake is engaged and wheels are blocked. Remove fuel filler cap. Warm up engine until it reaches normal operating temperature. 2) Check and adjust throttle sensor before adjusting idle speed. Disconnect vent and vacuum solenoid harness connector located near oil filler hole. See Fig. 4. Fig. 4: Vent and Vacuum Solenoid Harness Connector Disconnect harness before adjusting idle speed on EFI Models.
IDLE MIXTURE NOTE: Mixture adjustment is not part of normal tune-up procedure and should not be performed unless carburetor is overhauled or vehicle fails emissions testing. Carbureted Models 1) Idle mixture adjustment requires removal of carburetor to remove limiter cap. Using a hacksaw, cut through limiter cap and mixture screw 0.4" (10 mm) from cap end. Remove mixture screw and install new mixture screw. 2) To install new mixture screw, tighten screw lightly and ensure it is fully seated.
variable resistor to obtain highest idle speed. Turn air adjusting screw to set idle speed. Turn variable resistor counterclockwise until idle speed is 780 RPM and then turn resistor clockwise until idle speed is 800 RPM. 4) Connect vent and vacuum solenoid harness. Install plug over air adjusting screw. Fill space above variable resistor screw with adhesive (N304 23 795). Remove tachometer and install fuel filler cap. THROTTLE SENSOR Carbureted Models 1) Warm engine to normal operating temperature.
Remove tachometer. Fuel Injected Models 1) Warm engine to operating temperature. Stop engine and disconnect Green connector. Using 2 voltmeters, connect leads to Green connector terminals. See Fig. 9. Turn ignition on and observe voltmeters. Current should flow to 1 of the voltmeters. Fig. 9: Voltmeters Connected to Adjust Throttle Sensor This applies to fuel injected models. 2) If current flows to both voltmeters, remove throttle sensor adjusting screw cap and turn adjusting screw counterclockwise.
NOTE: Carburetor must be removed to check and/or adjust fast idle. Carbureted Models Only Adjust fast idle by setting angle of primary throttle valve with choke valve fully closed. Clearance between primary throttle valve and throttle bore should be .040-.047" (1.0-1.2 mm). If not to specification, bend fast idle rod until correct clearance is obtained. SERVICING EMISSION CONTROL See EMISSIONS section.
STARTER SPECIFICATIONS TABLE ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Volts Man. Trans. .......... Auto. Trans. ......... 11.5 11.5 Amps ........... ........... Test RPM 60 ................ 100 ............... 6500 3500 ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ ALTERNATOR All models are equipped with a Mitsubishi alternator.
FLUID CAPACITIES ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Application Quantity Crankcase (Includes Filter) Carbureted Models ................................ 4.9 qts. (4.6L) Fuel Injected Models ............................. 5.8 qts. (5.6L) Cooling System (Includes Heater) .................. 10.0 qts. (9.5L) Man. Trans. (SAE 90) ............................... 1.8 qts. (1.7L) Auto Trans. (ATF Type F) ........................... 7.9 qts. (7.5L) Rear Axle (SAE 90) Standard ..
1.2L ENG NO POWER/STUMBLE/ROUGH IDLE/BUCKING CAT. 4, NO. 014/85 Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:54PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN APPLICATION 1981-85 RX7 (High Altitude Vehicles) SUBJECT No Power, Stumble, Rough Idle, Bucking, Etc. REFERENCE Mazda Motors Corp., Service Bulletin, No.
1.2L HARD CRANK/NO START - CARBON IN ROTOR/HOUSING CAT. 1, NO. 103/83 Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:55PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN HARD CRANKING Models Bulletin No.
Fig. 2: Using Flywheel Turning Tool 5) Lower the vehicle. Turn the front pulley clockwise, facing the rear of the car, with a l9mm wrench. At the same time, inject 20-30 cc of engine oil through carburetor. Do not exceed the specified quantity of oil. 6) Turn the engine approximately five (5) revolutions to make certain the engine rotates freely. NOTE: Do not use the starter to rotate the engine. 7) Install the spark plugs. 8) Check that the battery is fully charged.
1.3L ENG NO START/BLOWN FUSE - SHORT IN WIRE HARNESS CAT. 15, NO. 012/85 Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:55PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN APPLICATION 1979-84 RX7 SUBJECT "ENGINE" Fuse Blows/No Start REFERENCE Mazda Motors Corp., Service Bulletin, No.
1.3L ENG SECONDARY AIR CONTROL SYSTEM MODIFICATION CAT. 4, NO. 002/84 Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:56PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN SECONDARY AIR CONTROL SYSTEM MODIFICATION Model: 1984 RX-7 (12A) Bulletin No.: 002/84 Date: 7/13/84 Category: 4 DESCRIPTION The Secondary Air Control System has been modified since the production date of March 1984. Now air is injected behind the No.
Fig. 2: Parts Information Table 1.3L ENG SECONDARY AIR CONTROL SYSTEM MODIFICATION CAT. 4, NO. 002/84 Article Text (p. Fig.
Checking Port Air Switching Valve: 1. Warm up the engine and run it at idling speed. 2. Connect a tachometer to the engine. 3. Disconnect the connector from the throttle sensor and connect a jumper wire to A and C terminals of the connector. Fig. 4: Jumper Wire Installation 4. Connect a voltmeter to the port air switching valve (R) terminal and ground. 5. Increase the engine speed and observe the voltmeter reading. Engine Speed (rpm) Idling speed - 3.000 3,000-4,000 more than 4.
forward. Fig. 6: Positioning Vehicle on Road Tester 8. Increase the vehicle speed and observe the voltmeter reading. Below 50 MPH - approx. 12V Above 50 MPH - below 2V Due to the addition of the Port Air Switching Valve in the Air Control Valve the wiring harness has been changed as shown in Fig. 7. 1.
Fig. 7: Wiring Harness Modifications 1.3L ENG SECONDARY AIR CONTROL SYSTEM MODIFICATION CAT. 4, NO. 002/84 Article Text (p. Fig.
1.3L ENG STALL/POOR IDLE - THROTTLE SENSOR ADJ CAT. 4, NO. 009/84 Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:56PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN IDLE SPEED ADJUSTMENT Model: 1984-1985 RX-7 (13B) Bulletin No.: 009/84 Date: 10/26/84 Symptom: Stall, Poor Idle Category: 4 DESCRIPTION Improper adjustment of the idle speed may cause poor idle stability or engine stall when coming to a stop.
Fig. 2: Checking Throttle Sensor Voltage (b) Terminal (A) - approximately 12v & Terminal(B) - approximately 12v: Throttle sensor out of adjustment. Adjust as follows: Turn the adjust screw counter-clockwise until the voltage at terminal(B) becomes 0. Then turn the adjust screw an additional 1/4 to 1/2 turn counter-clockwise. Confirm that the voltages at terminals (A) and (B) are as shown in Step 3(a). Fig.
Fig. 4: Disconnecting Solenoid Valves Connector Check the idle speed. Adjust the idle speed to specification, if necessary, by turning the air adjust screw. (Fig. 5) Idle speed: 800 rpm Fig. 5: Adjusting Idle Speed Use a jumper wire to ground the LW wire for the air supply valve as shown. Confirm that the engine speed increases to 1000-1070 rpm. ( Fig. 6) NOTE: Step 7 must be done with the connector for vent and vacuum solenoid valves disconnected Fig.
Fig. 7: Adjusting Engine Speed Reconnect the vent and vacuum solenoid valve connectors disconnected in Step 5. END OF ARTICLE 1.3L ENG STALL/POOR IDLE - THROTTLE SENSOR ADJ CAT. 4, NO. 009/84 Article Text (p.
BAD SHUTTER VALVE CAUSES ROUGH IDLE/NO IDLE Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 11:00PM ARTICLE BEGINNING TECHNICAL INFORMATION TIP ROTARY ROUGH IDLE YEAR(S): MANUFACTURER: MODELS: DATE OF ISSUE: ISSUE: 1982-85 Mazda RX-7 June 1993 BAD SHUTTER VALVE CAUSES ROUGH IDLE/NO IDLE A bad shutter valve may cause a rough or no idle on 1982-85 Mazda RX-7 models.
HI IDLE SPRRD OR HUNTING IDLE - NEW THROTTLE BODY CAT. 4, NO. 008/84 Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:57PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN HIGH IDLE SPEED OR IDLE SPEED HUNTING Model: Category: Bulletin No.
plug the inlet port of the vent solenoid valve with a finger as shown in Fig. 3 while the idle speed is high or hunting. Fig. 2: Disconnecting Vent Solenoid Valve Vacuum Hose If this procedure corrects the problem, the high idle is due to a faulty vent solenoid valve. Replace the vacuum switch valve (N304 13 240), which includes the vent solenoid valve, in this case. Fig.
TAS (THROTTLE ADJUSTMENT SCREW) LOCATION/ADJUSTMENT CAT. F, NO. 014/98 Article Text 1988 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Tuesday, June 11, 2002 09:33AM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN TAS (THROTTLE ADJUSTMENT SCREW) ADJUSTMENT Model(s): Category: Bulletin No.: Date: All Mazda Models with Fuel Injection F (01) - Fuel & Emission Control 014/98 December 9, 1998 VEHICLES AFFECTED All fuel injected models.
WHISTLE NOISE FROM CHECK &CUT VALVES - REPL VALVES CAT. 4, NO. 015/85 Article Text 1984 Mazda RX7 For iluvmyrx7.com Copyright © 1998 Mitchell Repair Information Company, LLC Saturday, June 08, 2002 10:59PM ARTICLE BEGINNING TECHNICAL SERVICE BULLETIN APPLICATION 1980-85 RX7 & 1981-85 GLC SUBJECT Whistle Noise From Check & Cut Valve REFERENCE Mazda Motors Corp., Service Bulletin, No.
