Mazda 1983 RX7 - Vacuum Diagrams

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VACUUM DIAGRAMS

Article Text

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 05:00PM

ARTICLE BEGINNING

1983 EXHAUST EMISSION SYSTEMS

Mazda Vacuum Diagram

RX7

VACUUM DIAGRAM

Main Page

Cruise Control System2
Description2
Operation2
Main/Control Switch2
Testing3
Wiring Diagram4
Instrument Panel - Standard5
Description and Operation5
Gauges5
Removal and Installation6
Instrument Cluster6
GLC Hatchback Removal/Installation6
GLC Wagon Removal/Installation6
Combination Switch7
Gauge Testing Needle Locations7
Wiper/Washer System8
GLC Wagon Operation8
Wiper Motor Testing8
All Other Models8
Front Wiper Motor Assembly9
Rear Wiper Motor Assembly9
Wiper Switch9
Mazda GLC Hatchback Wiring Diagram10
Mazda GLC Wagon Wiring Diagram10
Mazda RX7 Wiring Diagram11
Mazda B2000 and B2200 Wiring Diagram11
Mazda 626 Front Wiper Wiring Diagram12
Mazda 626 Rear Wiper Wiring Diagram13
Electrical Component Locator14
RX7 Component Locator Chart14
Miscellaneous Components14
Control Units15
Coolant Level Control Unit16
Control Processing Unit16
Cruise Control Unit16
Emission Control Unit17
Oscillator Control Unit17
Stop Light Checker18
A/C Relays18
Choke and Check Relay19
Horn Relay19
Hot Start Relay20
Power Antenna Relay20
Sending Units/Sensors21
Sending Units/Sensors22
Heat Hazard Sensor23
Oil Level Sensor23
Oil Pressure Sending Unit24
Oil Thermo Sensor25
Throttle Sensor25
Washer Fluid Level Sensor25
Solenoids/Solenoid Valves26
Leading Vacuum Control27
Leading Vacuum Control Solenoid, Valve28
Rear Hatch Release Solenoid28
Relief Solenoid Valve28
Shutter Solenoid Valve30
Trailing Vacuum Control Solenoid31
Back-Up Light Switch32
Brake/Stop Light Switch33
Clutch Switch33
Coolant Temperature Switch34
Inhibitor Switch34
Kickdown Switch34
Parking Brake Switch34
Alternator and Regulator35
Application35
On-Vehicle Test35
Overhaul Disassembly37
Diode Assemblies37
Rotor Field Continuity37
Component Replacement38
Reassembly38
Rotor Field Coil Ground38
Stator Coil Ground/Continuity38
Exploded View of Mitsubishi Alternator39
Fuse and Flasher Locations40
1983 Fuse Blocks, Flashers and Relays40
Component Location40
Fuses and Articles Breakers42
Fuse Panel Location42
Fuse Panel and Fuse Block Identification42
Fuses and Circuit Breakers42
Cautions and Warnings44
Brake Pad Wear Indicator44
Headlight Retractor44
Air Bag System44
Ignition System45
Schematic of RX7 Ignition System45
Operation45
Adjustments46
Reluctor-To-Pick-Up Coil Air Gap46
Ignition Timing46
High Tension Wire Resistance Check47
Ignition Coil Resistance Check47
Pick-Up Coil Resistance Check47
Pick-Up Coil Operation Check48
Igniter Check48
Ohmmeter Hookup for Pick-Up Coil Resistance Check48
Test Lamp Hookup for Checking Ignitor Operation48
Overhaul Reassembly49
Disassembled View of RX7 Mitsubishi Distributor49
Starter - Hitachi/Mitsubishi50
Mitsubishi Starter Application Table50
Starter Performance Tests50
Solenoid Tests51
Load (Lock Torque) Test51
Pull-In Coil Test51
Hold-In Coil Test52
Connections for Conducting Solenoid Pull-In Test52
Connections for Conducting Solenoid Hold-In Test52
Overhaul Disssasembly53
Return Test53
Connections for Conducting Return Test53
Cleaning and Inspection53
Bench Tests54
Brush Spring Tension Table54
Minimum Brush Length Table54
Commutator54
Overrunning Clutch Assembly55
Pinion Gear Clearance55
Pinion Case Bearing55
Measuring Pinion Edge-To-Pinion Stopper Clearance55
Disassembled View of Typical Mitsubishi Conventional Starter56
A/C System General Diagnostic Procedures57
Altitude Pressure Variations Table57
Altitude Vacuum Variations Table57
Preparation for Testing58
Air Conditioning System Performance Check Table58
Ambient Temperature /Pressure59
Air Conditioning Diagnosis with Gauges for Systems60
Evaporator Temperature/Pressure A/C Chart60
A/C System Precautions62
Before Opening the System62
Discharging A/C System62
Disconnecting Lines and Fittings62
Using R-12 Refrigerant - Safety Precautions63
Using Individual R-12 Cans63
Multi-Can Dispensing Valves63
Can Tap Installation Flat Type Seal Cans63
Screw Type Seal Cans64
Connecting Lines and Fittings64
Placing System in Operation64
Compressor Removal Informtaion - Isolation Method64
Compressor Removal Information - Discharge Method65
Transmission Removal and Installation66
Pickup Removal/Installation66
GLC (RWD) Removal66
GLC (RWD) Installation67
GLC (FWD) Removal/Installation67
Transmission Servicing - A/T68
Identification68
Lubrication68
Fluid Level68
Brake Band Adjustment69
Kickdown Switch and Downshift Solenoid69
Transaxle69
Shift Linkage70
Selector Lever Handle Adjustment70
Neutral Safety Switch70
Adjusting Neutral Safety Switch on RX7 Transmissions70
Brake System72
Rear Drum Brake Shoes72
Adjusting Rear Brake Shoe-To-Drum Position72
Brake Pedal Height Adjustment73
Parking Brake73
Brake Warning Light73
Front Disc Brake Pads Removal and Installation73
Rear Disc Brake Pads74
Front Disc Brake Caliper74
Rear Brake Caliper74
Front Disc Brake Rotor75
Rear Brake Drum75
Exploded View of GLC Wagon Rear Brakes75
Overhaul76
Rear Brake Shoes76
Master Cylinder76
Power Brake Unit76
Exploded View of Pickup Front Disc Brake Caliper77
Exploded View of RX7 Front Brake Caliper77
Rear Disc Brake Caliper77
Proper Installation of Conical Spring and Adjusting Bolt78
Wheel Cylinders79
Master Cylinder79
Exploded View of Wheel Cylinder79
Power Brake Unit80
Exploded View of Typical Master Cylinder80
Exploded View of Typical Power Brake Unit81
Torque Specifications82
Disc Specifications82
Drum Specifications83
1.1L Rotary84
Engine Coding84
Engine Removal and Installation84
Engine Identification84
Exploded View of Rotors and Eccentric Shaft Assembly85
Oil Pump Drive and Sprocket Removal86
Loosening Sequence of Tension Bolts87
Inspection and Overhaul88
Front, Intermediate and Rear Housings88
Extracting Tubular Dowels from Engine88
Straightedge Positions for Checking Housing Distortions88
Side Seal Step Wear Table89
Measuring Housing Wear with Dial Indicator89
Checking Side Seal Step Wear89
Oil Seal Step Wear90
Rotor Housing91
Stationary Gear Slot and Dowel Alignment91
Measuring Rotor Housing for Distortion91
Rotors92
Rotor Oil Seal92
Rotor Housing Thickness Check Points92
Measuring Point of Oil Seal Protrusion92
Rotor Bearing Replacement93
Apex Seal93
Pressing Rotor Bearing from Rotor93
Measuring Apex Seal Height93
Side Seal94
Corner Seal94
Apex Seal Warpage94
Measuring Free Height of Apex Seal Spring94
Eccentric Shaft95
Checking Corner Seal Groove Measurement95
Measuring Clearance of Apex, Side and Corner Seals95
Oil Seals Reassembly96
Installing Oil Seal Spring on Rotor96
Apex, Corner and Side Seals97
Installing Front Rotor97
Installing Assist Piece on Apex Seal97
Installing Eccentric Shaft98
Installing Front Rotor Housing98
Positioning Rotor Apex for Reassembly98
Applying Sealing Agent to Rotor Assembly98
Installing Protectors for Inner Sealing Rubbers99
Positioning Inner Sealing Rubber99
Installing Intermediate Housing100
Installing Rear Rotor and Housing100
Installing Rear Housing100
Tightening Tension Bolts100
Flywheel Counterweight Installation101
Eccentric Shaft End Play Adjustment101
Tightening Sequence of Tension Bolts101
Measuring Eccentric Shaft End Play102
Engine Oiling103
Crankcase Capacity103
Installing Front Cover and Eccentric Shaft Pulley103
Installing Oil Strainer and Oil Pan103
Oil Filter104
Normal Oil Pressure104
Engine Oiling System104
Oil Pump105
Mazda RX7 Engine Oiling System105
Measuring Oil Pump Drive Chain Slack105
Metering Oil Pump106
Exploded View of Oil Pump Assembly106
Adjusting Metering Pump Control Rod106
Oil Cooler107
Engine Cooling107
Thermostat107
Water Pump107
Pressure Cap107
Engine Specifications108
Exploded View of Water Pump108
Rotor Specifications109
Apex Seal Specifications109
Side Seal Specifications110
Shaft and Rotor Bearing Specifications110
Corner Seal Specifications110
Oil Seal Specifications110
Port Timing Specifications111
A-Engine/Vin ID112
Model Identification112
VIN Code ID Explanation112
VIN Code Identification112
Air Injection System114
Air Pump Test115
Check Valves Test115
Air Control Valve Test115
Relief Solenoid Valve Test116
Hose Arrangement for Checking116
Relief Solenoid Valve Signal Check Test117
Testing Relief Solenoid Valve117
Switching Solenoid Valve Signal Check Test118
Testing Relief Solenoid Valve Signal118
Heat Hazard Sensor Test119
Testing Switching Solenoid Valve119
Testing Heat Hazard Sensor120
Auxiliary Control Device121
Control Unit121
Terminal Locations of Control Unit and Throttle Sensor121
Choke Relay122
Choke Switch122
Choke Relay Terminal Locations122
Choke Switch Terminal Locations122
Water Temperature Switches123
Control Unit Testing124
Carburetor - NIKKI 4-BBL125
Float Level125
Float Drop125
Float Level Adjustment125
Choke Linkage126
Choke Valve Opening Angle126
Float Drop Adjustment126
No. 2 Choke Diaphragm127
Choke Diaphragm Operation127
Checking Choke Delay Valve Operation127
Choke Valve Opening Angle Adjustment127
Checking Automatic Choke Release128
Checking Carburetor Heater128
Hot Start Assist Cable128
Throttle Opener129
A/C Models Only129
Hot Start Assist Cable Adjustment129
Throttle Opener Adjustment129
Checking Altitude Compensator130
Accelerator Cable Adjustment130
Adjusting Accelerator Cable and Pedal Height130
Removing Jets and Air Bleeds131
Adjustment Specification132
Choke - Electric Assist133
Choke Return System133
Hot Start Assist System133
Choke Return and Hot Start Assist Systems134
Engine Temperature Indication for Release of Choke Knob134
Choke Magnet135
Hot Start Assist Relay135
Choke Switch Terminal Numbering135
Hot Start Assist136
Adjusting Hot Start Relay Cable136
Deceleration Control System137
No.1 Anti-Afterburn Valve137
Operation137
No.2 Anti-Afterburn Valve138
Testing No. 1 Anti-Afterburn Valve138
Throttle Sensor138
Testing Throttle Sensor139
Shutter Solenoid Valve Signal Check140
Testing Shutter Solenoid Valve140
Coasting/Shutter Valve141
Dashpot141
Testing Shutter Solenoid Valve Signal141
Emission Application143
Emission Control Device Applications143
Abbreviation Definitions143
Fuel Evaporatijn System145
Air Vent System145
Mazda RX7 Check and Cut Valve145
Check and Cut Valve146
Evaporative Line Check146
Mazda RX7 Air Vent and Fuel Evaporation System146
Air Vent Solenoid Valve147
Maintenance147
Fuel Pump - Electric148
Pressure Test148
Volume Test148
Fuel Pump149
Hot Idle Compensation System150
Mazda Hot Idle Compensator Valve150
Idle Compensation System151
Idle Compensator Operation151
Altitude Compensator Operation151
Throttle Opener Operation151
Idle Compensator Test152
Altitude Compensator Test152
Air Conditioner Solenoid Valve Test153
Air Conditioner Solenoid Valve Signal Check Test154
Air Conditioner Relay Test154
Throttle Opener Test155
Air Conditioner Relay Terminals155
PCV System156
Piston Engines156
Rotary Engines156
Diesel Engine156
Piston Engines Testing157
Rotary Engines Testing157
B2000 Pickup Crankcase Ventilation System157
RX7 Rotary Engine Purge Valve158
GLC and 626 Crankcase Ventilation System158
B2200 Diesel Pickup Crankcase Ventilation System158
Spark Control System159
Vacuum Control Solenoid Valve159
Vacuum Control Solenoid Valve Signal Check159
Testing Vacuum Control Solenoid Valve160
Tune-Up - Rotary161
Engine Identification161
Engine Compression161
Compression Specifications161
High Tension Wire Resistance162
Distributor Adjustment162
Ignition Timing Adjustment162
Firing Order and Distributor Rotation162
Tune-Up - Rotary162
Idle Speed and Mixture163
Connecting Timing Light163
Ignition Timing Mark Location163
Idle Speed and Mixture Specifications164
Carburetor Adjusting Screw Locations164
Cold (Fast) Idle RPM165
Servicing165
Emission Control165
Specifications165
Starter Specifications166
Service Specifications166
Vacuum Diagrams168
Mazda RX7 Rotary Engine Vacuum Diagram169
Maintenance Information170
VIN Location170
Maintenance Service Information171
Severe and Normal Service Definitions171
Service Point Locations172
Information Label Locations175
Information Label Locations176
Service Labor Times176
Lubrication Specifications176
Fluid Capacities177
Wheel and Tire Specifications177
Tire Inflation Specifications178
Wheel Tightening178
Battery Specifications178
Supplemental Restraint System (Air Bag)178
Anti-Lock Brake System179
Battery Warning179
Replacing Blown Fuses179
Catalytic Converter179
Coolant180
Electrostatic Discharge Sensitive Parts180
Fuel System Service180
Halogen Bulbs180
Radiator Cap/Fan181
Turbocharged Models181
Fuses and Circuit Breakers182
Emission Control System182
Fuse Panel Identification (1983-85)183
Fuse Block Identification (1983-85)183
Fuse Panel and Fuse Block Identification (1986-90)184
Fuse Panel and Fuse Block Identification (1991)186
Scheduled Services189
Cautions and Warnings189
Anti-Lock Brake System189
Radiator Fan192
Severe Service Requirements (Perform W/Service Schedules)196
Normal Maintenance Service Schedules198
Service Indicator and Warning Lights225
Dash Gauges and Warning Lights225
Transmission Removal and Installation - M/T227
Transmission Servicing - M/T228
Service Intervals228
Fluid Type228
Linkage228
Clutch Assembly229
Release Bearing and Fork230
Exploded View of RWD Clutch Assembly230
Clutch Master Cylinder231
Clutch Slave Cylinder231
Clutch Cable231
GLC Wagon Clutch Cable Assembly231
Pilot Bearing232
Flywheel232
Exploded View of Clutch Master Cylinder233
Clutch Pedal Height234
Clutch Pedal Free Play234
Exploded View of Clutch Slave Cylinder234
Clutch Pedal Height Specifications235
Clutch Adjustment Locations235
Drive Axle236
Axle Ratio and Identification236
Exploded View of Mazda Rear Axle Assembly236
Axle Shafts and Bearings237
Exploded View of Axle Shaft Assembly237
Differential Carrier238
Exploded View of Axle Shaft Assembly for Pickups238
Case Assembly239
Drive Pinion Depth240
Dummy Pinion Shaft and Gauge Block240
Pinion Depth Adjusting Shims241
Measuring Drive Pinion Installed Height241
Initial Pinion Nut Torque242
Pinion Bearing Preload242
Installing Drive Pinion Bearing Collapsible Spacer242
Axle Assembly Specifications243
Backlash and Side Bearing Preload243
Adjusting Differential Bearing Preload243
Steering Column245
GLC Wagon Steering Column246
Torque Specifications246
Steering Column Switches247
Steering Wheel and Combination Switch247
Ignition Switch247
Typical Mazda Steering Wheel Assembly247
Steering Lock248
Exploded View of Ignition Switch248
Steering Gear - Manual249
Exploded View of Steering Gear Assembly250
Steering Linkage251
Worm Bearing Preload252
Sector Shaft End Play252
Steering Gear Backlash252
Checking Sector Shaft Adjusting Screw End Clearance252
Final Worm Bearing Preload Table253
Suspension - Front254
Wheel Bearing Adjustment254
Ball Joint Checking254
Wheel Bearing Removal and Installation255
Lower Control Arm255
Strut Assembly255
Front Suspension255
Strut Reservoir Volume Table256
Suspension - Rear258
Coil Spring Removal and Installation258
RX7 Rear Suspension Assembly258
Shock Absorber259
Upper/Lower Links and Watt Links259
Stabilizer Bar259
Jackking and Hoisting261
Frame and Underbody261
Outerbody261
Floor Jack, Floor Hoist and Vehicle Jack261
B2000 and B2200 Lifting Points262
GLC and 626 Lifting Points262
GLC Wagon Lifting Points262
RX7 Lifting Points263
Pre-Alignment Checks264
Wheel Alignment Specifications and Procedures265
Tire Inflation265
Caster265
Macphearson Strut Support Table265
Camber266
Toe-In266
GLC FWD and 626266
Wheel Alignment Specifications Table267
GLC and 626 Star Wheel Adjustment267
1.3L Eng no Start/Blown Fuse269
Condition and Cause269
Repair269
View of Wiring Harness269
Acceptable Battery Drain270
Technical Service Bulletin270
Current Draw from the Battery270
Current Draw Amperage270
Test Procedures270
Testing Currant Draw271
Alternator/Regulator Test Process/Replacement272
IC Regulator Checking Procedure272
Parts Information272
Exploded View of Alternator272
Article Beginning272
Repair Procedure273
Location of "F" Terminal273
Proper Location of Insulators273
Audio System Troubleshooting Procedures274
Battery Removal/Install Wire Clip Warning276
Battery Clamp Bolt and Nut276
Fusible Link Reference Chart277
Service Information277
High Pitch Buzzing Noise at Dash: Remove Oscillator279
Technical Information Tip279
Keyless Switch Speed Nut Information280
Speed Nut for Ignition Key Switch280
Securing Key-Less Switch with Speed Nut280
Miscellaneous Blown Fuses/Electrical Problems281
View of Rear Wiring Harness281
Rear Window Defroster Grid Line Repair Procedure282
Resin Application Location282
Warranty Information283
Revised Wiper Link Bushing284
1981-85 RX7 Wiper Link284
Turn Signal Doesn't Cancel285
Turn Signal Switch Cancel Cam285
Steering Wheel Removal285
Turn Signal Cancel Cam286
Removing Cancel Cam from Switch286
Torque Specification286
Aligning Cancel Cam Tabs287
1.2L Eng Modified A/C Compressor Bracket Instruction288
A/C Compressor Bracket Installation288
VIN of Production Change288
Installation of A/C Compressor Bracket288
Article Beginning288
Parts Information289
A/C Lite DIM/Not On-Wire Harness Connector290
Air Conditioner Indicator Light290
A/C Indicator Light Harness Routing290
RX7 A/C Accessory Connectors291
Correct Freon Charge Warning Specs292
Refrigerant Charge Service292
Quick Visual Check292
A/C Charging Sight Glass Symptoms292
Heating System Troubleshooting293
Heating and Defroster Troubleshooting Manual293
Using this Manual294
Climate Control System294
Customer Comment Sheet295
Check Sheet297
Heater Concern297
Diagnostic Flow Chart297
Measuring Vent Outlet Air Temperature297
Air Leakage298
Link and Wire Adjustment299
Coolant By-Passing the Thermostat/Thermostat Stuck299
Blower Unit Linkage Adjustment299
Heater Unit Linkage Adjustment299
Recommended Climate Control System Operation300
Air Intake Selector300
Function Selector301
Temperature Selector Lever301
Temperature Selector302
Climate Control System Layout302
Inoperative A/C - Blown Fusible Receiver/Dryer Plug303
Poor A/C Cooling - Adjust A/C Thermostat304
Nippondenso Air Conditioner304
Removing Glove Box and under Cover304
Repair Procedure304
Removing 2 Screws Securing the Thermostat305
Adjusting Thermostat305
Poor Cooling - Diagnosing/Repair A/C Leaks306
Diagnosis and Repair of A/C Refrigerant Leaks306
Verify the Customer's Complaint306
Verify the State of Charge Amount306
Investigation and Repair307
Leak Test307
Freon Detector Inspection Angle307
Damaged Component Illustration307
Receiver Drier Replacement Criteria308
Use of A/C Tracer Dye Service Info312
When Using A/C Tracer Dye Method312
Tracer Dye Suppliers313
Refrigerant/Compressor Oil313
Use of R-12 Refrigerant Substitutes315
L4N71B Trans Oil Pressure Gauge Adapter316
Oil Pressure Gauge Adaptor Installation316
Painting Rustproof Steel Panels317
Painting Rustproof Steel Panels Location Table317
Location of Rustproof Steel Panels on 3 and 5-Dr Hatchbacks319
Mazda 323 Wagon - Rustproof Body Panels320
Mazda 626/MX-6 - Rustproof Body Panels321
Mazda RX-7 - Rustproof Body Panels322
Mazda 929 - Rustproof Body Panels323
Mazda MPV - Rustproof Body Panels324
Mazda "B" Series - Rustproof Body Panels325
Static Electricity Shock When Exiting Vehicle326
Recommended Anti-Static Products326
Whistle Noise from Check and Cut Valves327
Anything Installation327
Wind Noise Around Doors328
Card Test328
Repair Procedure328
White Grease Test329
Door Adjustment329
Grease Pattern - Measure331
Hinge Mount - Outline331
Windshield Stone Chipping Inspection332
Inspection Procedure332
Brake Caliper Bolt Corrosion333
Brake Judder Repair334
Causes of Judder334
Correction334
Service Tools336
Warranty Information336
Vibration/Pulsation While Braking337
Brake Drums Labor Operation/Time Codes - 1993/95 Models339
Rear Disc Brakes Labor Operation/Time Codes341
Front Brakes Labor Operation/Time Codes - 1993/95 Models344
1.2L Eng Cooling Fan Drive - New Grease for Cold348
1983 RX-7 Cooling Fan Drive348
Location of Bearing in Fan Drive348
1.2L Hard Crank/No Start - Carbon in Rotor/Housing349
Hard Cranking349
View of Flywheel Turning Tool349
Using Flywheel Turning Tool350
Removing Inspection Plate from Convertor Housing350
1.3L Eng Clutch VIB - Repl Flywheel Alignment Pins352
Clutch Alignment Pins352
83-86 RX7 Flywheel and Alignment Pins352
Bad Shutter Valve Causes Rough Idle/No Idle353
Rotary Rough Idle353
Engine Stand Adaptor Modifications354
Filling Cooling System355
Caution When Adding Coolant355
Caution When Replacing Coolant355
View of Coolant Reservoir355
Engine Coolant355
Installing Mazda Brand Oil Filter357
Installation Instructions Found on the Filter Boxes and the Filters357
Engine Oil Filter Cartridge357
All Models357
Installation Procedure357
Oil Leak at Rear Stationary Gear O-Ring - Car Fix359
On-Car Replacement Procedure359
Repair Procedure359
Rear Stationary Gear, Oil Seal and Bolt - Insert Screwdrivers360
Rear Stationary Gear, Oil Seal and Bolt - Remove and Clean360
Parts Information360
New Engine Replacement Program362
B-Trucks New Engine Availability Parts Table362
Partial Engine (Long Block) Availability362
Propylene Glycol Based Coolant367
Affected Models367
Rattle from Floor When Accel - Broken Muffler Hanger368
Pre-Silencer Hanger Breakage368
View of Pre-Silencer with Stiffener368
Reconditioned Anti-Freeze369
Reconditioned Anti-Freeze Warnings370
Revised Rotory Engine Pricing371
1.2L Eng no Power/Stumble/Rough Idle/Bucking373
1,2L New Throttle Sensor Adjusting Procedure374
View of Test Connections in 1982 and 1983 Models374
1.3L Eng Throttle Sensor Tool and Adjustment375
Checking Throttle Sensor375
RX7 Throttle Adjusting Tools375
RX7 Throttle Sensor Checker Hookups375
Adjusting Throttle Sensor376
Throttle Sensor Testing376
Throttle Sensor Checker Attachments377
Throttle Sensor Adjusting Positions377
California Reformulted Gasoline378
Background378
Mazda's Position on Carfg378
Difference between Carfg and Other Gasolines378
Carfg Affect on Vehicle Performance379
Carfg Affect on Fuel Economy379
No Special Additives Are Necessary When Using Carfg379
Older Vehicle's Performance Using Carfg379
Odor Emitted from Carfg380
Additional Information Regarding Carfg380
Choke System Maintenance Shedule/Cleaning Procedure381
Spraying Cleaner on Carburetor381
Article Beginning381
Emission Inspection and Maintenance Test Preparations382
Proper Preparation for State Emission Inspection and Maintenance Test382
Preparation Procedure382
Parts Bulletin - Spark Plug Coil/Wire383
Recommended Fuel386
Use of Regular Unleaded Gasoline386
RX-7 Oil Replacement Tip387
RX-7 Oil Filter Replacement387
Spark Plugs for Piston Engines388
Spark Plug Cross-Reference Chart388
Spark Plug Identification for 1986-91 RX-7 Engines390
TAS Location/Adjustment391
Vehicle Affected391
Throttle Adjustment Screw Locations392
1.2/1.3 L Eng Clutch Chatter/Judder394
Hard Shift to 2Nd Gear after Cold Start396
2Nd Gear Synchronizer Ring and Assembly396
Warranty Information397
Improved Speedo Gear Sleeve to Eliminate Leaks398
Speedometer Driven Gear Sleeve398
VIN of Production398
Speedometer Gear Sleeve and Gasket Modifications398
M and R Type Trans Hard Shift Cold400
Hard Shift in Low Temperature400
Manual Trans New Bearing Cover Bolts/Torque401
Modification of Bearing Cover Bolts401
Bolt Information Table401
VIN of Product Change401
Manual Transmission Shim Adjustments403
Manual Transmission Application Chart404
Manshaft Rear Bearing405
Retaining Ring Installation405
Measuring Clearance between Thrust Washer and "C" Washer405
R-Type406
Installing Rear Bearing406
Measuring Clearance between "C" Washer and Rear Bearing406
Mainshaft Rear Bearing407
Measuring Clearance between "C" Washers and Thrust Washer407
Rear Bearing Installation408
Measuring Clearance Between"C" Washer and Rear Bearing408
Remanufactured Trans - Diagnosis Sheet409
Rear Wheel Drive Pinion Height Adjustment413
Location of Adjustment Numbers413
Alignment Specifications414
New Specifications Table414
Vehicle Preparation and Condition415
Caster Specification Table415
Alignment Specifications and Tolerances416
Caster Example Table417
Aluminium Wheel Tire Change - Center Hub Damage Info418
RX7, 626 and GLC Aluminum Wheel418
Article Beginning418
Checking Procedure for Power Steering Boot Leakage419
Power Steering Gear and Boot Wire - Inspect Fluid Leakage420
High Steering Wheel Effort - Verify Condition421
Installation of Tire Chains422
Revised Idler Arm/Dust Seal423
Idler Arm Modification423
Steering Wheel Slightly off Center424
Tie Rod Circumference Distance Table424
Catalyst Pellets and Modification of Secondary Air Sys426
Mazda RX-7 Exhaust Emission System Recall Campaign426
Defect Information Report426
EPA Recall Surveillance Test Results426
Voluntary Emission Recall Report427
Recall Campaign Bulletin428
Subject Vehicles428
Notification429
Campaign Parts429
Recall Parts Kit429
Related Parts429
Parts Information429
Exchange Units of Converter Housing430
Air Control Valve Components430
Installation of Secondary Air Orifice431
Repair Procedures431
Inspection and Adjustment of Choke Wire432
Disconnecting Hose from Air Pump432
Air Hose with Orifice Installed432
Air Control Valve (ACV)433
Measuring Clearance between Lock Nut and Bracket433
Checking Choke Valve Opening433
Hot Air Duct Location434
Disconnecting Air Hose between Air Cleaner and ACV434
Sliding Clamp on Air Hose435
Proper Check Valve Orientation435
Removing Cap and Switching Valve436
Location of Hole for Enlargement436
Blowing Chips off with Air Gun437
Replacement of the Catalyst Pellets438
Check Valve Position and Orientation438
Location of Drain Plugs No. 1 and 2439
Proper Positioning of Converter in a Vise439
Converter in Level Position440
Installing New Lock Washer on Converter440
Replacement of the Catalytic Converter441
Location of Drain Hole No. 2441
Distribution of New and Old Pellets in Converter441
Location of Protector No. 2442
Removing Silencer Hangers442
Bending Back Tip of Exhaust Pipe Lowe Cover443
Removing Catalytic Converter444
Tightening Flange Nuts445
Location to Affix Recall Label446
Tagging Returnable Pellets446
Idler Arm Pin Breakage Could Cause Loss of Steering449
NHTSA Recall Bulletin449
Vehicle Description449
Description of Deffect449
Wiring Diagram Symbols450
How to Use the Wiring Diagrams450
Color Abbreviation Identification451
Identifying Tie-Off Symbols451
Identifying Option Symbols451
Wiring Diagram Symbol Identification452
Wiring Diagrams455
Engine Compartment455
Fuse Block and Underdash456
Underdash and Instrument Panel457
Rear Compartment and Accessories458

Mazda 1983 RX7 - Vacuum Diagrams

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