Mazda 2006-2008 RX7 Engine Manuel d'instructions

Title Section

GENERAL INFORMATION 00

ENGINE 01

CONTENTS

Engine

Workshop

Manual

FOREWORD

This manual explains the service points for

the above-indicated automotive system.

This manual covers all models with the

above-indicated automotive system, not any

one specific model.

In order to do these procedures safely,

quickly, and correctly, you must first read

this manual and any other relevant service

materials carefully.

All the contents of this manual, including

drawings and specifications, are the latest

available at the time of printing.

As modifications affecting repair or

maintenance occur, relevant information

supplementary to this volume will be made

available at Mazda dealers. This manual

should be kept up-to-date.

Mazda Motor Corporation reserves the right

to alter the specifications and contents of

this manual without obligation or advance

notice.

be reproduced or used in any form or by any

means, electronic or mechanical—including

photocopying and recording and the use of

any kind of information storage and retrieval

system—without permission in writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

PRINTED IN U.S.A., AUGUST 2005

Form No. 1866–1U–05H

Part No. 9999–95–LFL3–05

GENERAL INFORMATION

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SECTION

00–00

To c o f S C T

GENERAL INFORMATION . . . . 00-00

To c o f S C T

00–00 GENERAL INFORMATION

HOW TO USE THIS MANUAL . . . . . . . . . 00–00–2

Range of Topics . . . . . . . . . . . . . . . . . . 00–00–2

Service Procedure . . . . . . . . . . . . . . . . 00–00–2

Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–4

Advisory Messages. . . . . . . . . . . . . . . . 00–00–4

UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–5

Conversion to SI Units (Système

International d'Unités) . . . . . . . . . . . . . 00–00–5

Rounding Off . . . . . . . . . . . . . . . . . . . . . 00–00–5

Upper and Lower Limits . . . . . . . . . . . . 00–00–5

FUNDAMENTAL PROCEDURES. . . . . . . 00–00–6

Preparation of Tools and Measuring

Equipment. . . . . . . . . . . . . . . . . . . . . . 00–00–6

Special Service Tools . . . . . . . . . . . . . . 00–00–6

Disassembly . . . . . . . . . . . . . . . . . . . . . 00–00–6

Inspection During Removal,

Disassembly . . . . . . . . . . . . . . . . . . . . 00–00–6

Arrangement of Parts . . . . . . . . . . . . . . 00–00–7

Cleaning of Parts . . . . . . . . . . . . . . . . . 00–00–7

Reassembly . . . . . . . . . . . . . . . . . . . . . 00–00–7

Adjustment . . . . . . . . . . . . . . . . . . . . . . 00–00–7

Rubber Parts and Tubing . . . . . . . . . . . 00–00–8

Hose Clamps . . . . . . . . . . . . . . . . . . . . 00–00–8

Torque Formulas . . . . . . . . . . . . . . . . . 00–00–8

Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–8

ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–9

Connectors. . . . . . . . . . . . . . . . . . . . . . 00–00–9

NEW STANDARDS . . . . . . . . . . . . . . . . . 00–00–11

ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–12

End of Toc

GENERAL INFORMATION

00–00–2

HOW TO USE THIS MANUAL

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Range of Topics

•This manual contains procedures for performing all required service operations. The procedures are divided

into the following five basic operations:

—Removal/Installation

—Disassembly/Assembly

—Replacement

—Inspection

—Adjustment

•Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of

parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.

Service Procedure

Inspection, adjustment

•Inspection and adjustment procedures are

divided into steps. Important points regarding the

location and contents of the procedures are

explained in detail and shown in the illustrations.

49 H002 671

49 H032 322

49 1232 670A

SHOWS PROCEDURE ORDER

FOR SERVICE

Fluid Pressure Inspection

1. Assemble the SSTs as shown in the figure.

Tightening torque

SHOWS TIGHTENING

TORQUE

SPECIFICATIONS

Caution

Connect the gauge set from under

the vehicle to prevent contact with

the drive belt and the cooling fan.

39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}

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GENERAL INFORMATION

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Repair procedure

1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit

together, and describes visual part inspection. However, only removal/installation procedures that need to be

performed methodically have written instructions.

2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview

illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also

shown.

3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration

with the corresponding number. Occasionally, there are important points or additional information concerning a

procedure. Refer to this information when servicing the related part.

GREASE

SHOWS NON-REUSEABLE PARTS

SHOWS DETAILS

KNUCKLE

UPPER TRAILING LINK

LOWER TRAILING LINK

SST

N·m {kgf·m, ft·lbf}

118—156 {12.0—16.0, 87—115}

94—116 {9.5—11.9, 69—86}

43—56 {4.3—5.8, 32—41}

49 T028 304

49 T028 305

49 T028 303

Procedure

LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION

1. Jack up the rear of the vehicle and support it with safety stands.

2. Remove the undercover. (See 01-10-4 Undercover Removal)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Inspect the rear wheel alignment and adjust it if necessary.

1Split pin

2Nut

3Lower trailing link ball joint

(See 02-14-5 Lower Trailing Link Ball Joint Removal Note)

Bolt

5Lower trailing link

6Dust boot (lower trailing link)

7Split pin

8 Nut

9 Upper trailing link ball joint

(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)

10 Nut

11 Upper trailing link

12 Dust boot (upper trailing link)

Lower Trailing Link Ball Joint, Upper Trailing Link

Ball Joint Removal Note

Remove the ball joint using the SSTs.

—44—60 {4.4—6.2, 32—44}

"Removal/Installation"

Portion

"Inspection After

Installation" Portion

INSTALL THE PARTS BY

PERFORMING STEPS

1—3 IN REVERSE ORDER

SHOWS PROCEDURE ORDER

FOR SERVICE

SHOWS TIGHTENING

TORQUE

SPECIFICATIONS

SHOWS SERVICE

ITEM (S)

INDICATES ANY RELEVANT

REFERENCES WHICH NEED

TO BE FOLLOWED DURING

INSTALLATION

SHOWS SPECIAL

SERVICE TOOL (SST)

FOR SERVICE OPERATION

SHOWS APPLICATION

POINTS OF GREASE, ETC.

SHOWS TIGHTENING

TORQUE UNITS

SHOWS SPECIAL

SERVICE TOOL (SST)

NO.

SHOWS REFERRAL

NOTES FOR

SERVICE

SHOWS THERE

ARE REFERRAL

NOTES FOR SERVICE

BHE0000W104

GENERAL INFORMATION

00–00–4

Symbols

•There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols

show application points or use of these materials during service.

Advisory Messages

•You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this

manual.

Warning

•A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution

•A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note

•A Note provides added information that will help you to complete a particular procedure.

Specification

•The values indicate the allowable range when performing inspections or adjustments.

Upper and lower limits

•The values indicate the upper and lower limits that must not be exceeded when performing inspections or

adjustments.

End Of Sie

Symbol Meaning Kind

Apply oil

New appropriate

engine oil or gear

oil

Apply brake fluid New appropriate

brake fluid

Apply automatic

transaxle/

transmission fluid

New appropriate

automatic

transaxle/

transmission fluid

Apply grease Appropriate

grease

Apply sealant Appropriate

sealant

Apply petroleum

jelly

Appropriate

petroleum jelly

Replace part O-ring, gasket,

etc.

Use SST or

equivalent Appropriate tools

OIL

BRAKE

FLUID

GREASE

SEALANT

SST

GENERAL INFORMATION

00–00–5

00–00

UNITS

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Conversion to SI Units (Système International d'Unités)

•All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted

from these values.

Rounding Off

•Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit

value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and Lower Limits

•When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is

an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI

unit value may differ after conversion. For example, consider 2.7 kgf/cm

in the following specifications:

210—260 kPa {2.1—2.7 kgf/cm

, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm

, 39—45 psi}

•The actual converted values for 2.7 kgf/cm

are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as

an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is

used as a lower limit, so the converted values are rounded up to 270 and 39.

End Of Sie

Electric current A (ampere)

Electric power W (watt)

Electric resistance ohm

Electric voltage V (volt)

Length mm (millimeter)

in (inch)

Negative pressure

kPa (kilo pascal)

mmHg (millimeters of mercury)

inHg (inches of mercury)

Positive pressure

kPa (kilo pascal)

kgf/cm

2(kilogram force per square

centimeter)

psi (pounds per square inch)

Number of

revolutions rpm (revolutions per minute)

To r q u e

N·m (Newton meter)

kgf·m (kilogram force meter)

kgf·cm (kilogram force centimeter)

ft·lbf (foot pound force)

in·lbf (inch pound force)

Volume

L (liter)

US qt (U.S. quart)

Imp qt (Imperial quart)

ml (milliliter)

cc (cubic centimeter)

cu in (cubic inch)

fl oz (fluid ounce)

Weight g (gram)

oz (ounce)

GENERAL INFORMATION

00–00–6

FUNDAMENTAL PROCEDURES

E5U000000000E03

Preparation of Tools and Measuring Equipment

•Be sure that all necessary tools and measuring

equipment are available before starting any work.

Special Service Tools

•Use special service tools or equivalent when they

are required.

Disassembly

•If the disassembly procedure is complex,

requiring many parts to be disassembled, all parts

should be marked in a place that will not affect

their performance or external appearance and

identified so that reassembly can be performed

easily and efficiently.

Inspection During Removal, Disassembly

•When removed, each part should be carefully

inspected for malfunction, deformation, damage

and other problems.

CHU0014W003

49 SE01 310

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GENERAL INFORMATION

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Arrangement of Parts

•All disassembled parts should be carefully

arranged for reassembly.

•Be sure to separate or otherwise identify the parts

to be replaced from those that will be reused.

Cleaning of Parts

•All parts to be reused should be carefully and

thoroughly cleaned in the appropriate method.

Warning

•Using compressed air can cause dirt and

other particles to fly out causing injury to

the eyes. Wear protective eye wear

whenever using compressed air.

Reassembly

•Standard values, such as torques and certain

adjustments, must be strictly observed in the

reassembly of all parts.

•If removed, the following parts should be replaced

with new ones:

—Oil seals

—Gaskets

—O-rings

—Lockwashers

—Cotter pins

—Nylon nuts

•Depending on location:

—Sealant and gaskets, or both, should be

applied to specified locations. When sealant

is applied, parts should be installed before

sealant hardens to prevent leakage.

—Oil should be applied to the moving

components of parts.

—Specified oil or grease should be applied at

the prescribed locations (such as oil seals)

before reassembly.

Adjustment

•Use suitable gauges and testers when making

adjustments.

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GENERAL INFORMATION

00–00–8

Rubber Parts and Tubing

•Prevent gasoline or oil from getting on rubber

parts or tubing.

Hose Clamps

•When reinstalling, position the hose clamp in the

original location on the hose and squeeze the

clamp lightly with large pliers to ensure a good fit.

Torque Formulas

•When using a torque wrench-SST or equivalent

combination, the written torque must be

recalculated due to the extra length that the SST

or equivalent adds to the torque wrench.

Recalculate the torque by using the following

formulas. Choose the formula that applies to you.

A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.

Vise

•When using a vise, put protective plates in the

jaws of the vise to prevent damage to parts.

End Of Sie

WGIWXX0034E

WGIWXX0035E

Torque Unit Formula

N·m N·m ×[L/(L+A)]

kgf·m kgf·m ×[L/(L+A)]

kgf·cm kgf·cm ×[L/(L+A)]

ft·lbf ft·lbf ×[L/(L+A)]

in·lbf in·lbf ×[L/(L+A)]

SST

WGIWXX0036E

PROTECTIVE PLATES

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