Second Generation RX-7 Frequently Asked Questions

Introduction:

As the title makes fairly clear, this is the Second Generation RX-7 FAQ. This latest edition of the FAQ, version 3.0, contains a number of new articles, and substantial rewrites of older articles. The breakdown of the sections is basically the same, and for the most part the same topics are covered simply in deeper depth. The most significant addition to this edition of the FAQ is the graphics. Thanks to some of the more technically inclined RX-7 fans out there, there are color coded wiring diagrams, and color photographs of disassembled electrical components to go along with all new instructions for repairs and installation of aftermarket equipment. For what it's worth, the usual disclaimers are here. If you screw up your car while following directions from this text, it is your problem. No warranty or suitability of this product for your intended use is either expressed or implied. If you intend to do any real work on your car, order the factory workshop manual. Call Helm Publishing at 1-800-782-4356, or order it from MazdaTrix.

Before you attempt any of the fixes in this document, you should have the following tools at your disposal: screwdrivers (assorted Phillips and flathead sizes, you will need stubby screwdrivers as well, although a power screwdriver bit in a socket wrench will work), Socket Set and wrenches (you will need most of the metric sizes, 7mm (alternator ground nut) up to 22mm (lock nut for belt pulley), wrenches from 10mm (almost everything on the car) up to 19mm (exhaust stud nuts), soldering tools (Weller self-adjusting with microelectronics tip preferred, but a radio shack will do; Radio Shack metallic blue desoldering tool preferred, or generic desoldering bulb; 24 gauge fine solder preferred, generic solder will do; Panavise soldering bench vice w/circuit board holder makes the job MUCH easier, but you can just lay the boards flat on your workbench), various expletives of both common and obscure etymology, and some wire cutters (Craftsman, of course).

Section I

Second Generation RX-7 Problem Categories

Electrical

Cold solder points in CPU

Cold solder points in Clock/IdiotLight module

Cold solder points and/or blown transistors in Logicon (The climate control unit)

3800 RPM Hesitation

Shift up light malfunction

Light Switch Failure

Wiper Switch Failure

Mechanical

Seat Adjust Mechanism failure/jamming

Power Antenna failure

Parking Brake cable failure/seizure

Exterior door handle failure

Sticking sunroof

Worn out shift lever bushings

Body

Rusting exterior window trim

Cracked/Faded plastic Turbo hoodscoop

Electrical

Rusted out catalytic converter shield

Rusted out mufflers



Section II

How to fix your broken Rotary Rocket

CPU Cold Solder points fix ( David Disney)

NOTES:

A) Its a good idea to disconnect your battery when doing any kind of electrical work on your car.

B) When resoldering these circuitboards, don't use a mega-huge, three million watt soldering iron. You'll just end up making a mess. The usual five dollar Radio Shack soldering irons work just fine. Also, if you have never soldered before, you'd better get some practice before you delve into your beloved Rx-7's CPU. It will help to have either a solder suction pump or a solder wick.

Here We go!

1) Remove the Driver's Side Kickrail

Its the long plastic piece that mounts immediately below the door (See Figure 1). After removing all of the screws in the kickrail (there are four or five), you must pop the kickrail up, away from the vehicle. There are several metal clips under the kickrail that hold it down, so you will have to provide a pretty good amount of upward pressure, but be careful that you don't pull too hard on either end of the rail or it could break. I haven't broken one yet (they seem to be pretty tough), but I'm sure it can happen.

(FIGURE 1)



2) Remove Plastic Side Panel

Take a look at the plastic side panel on the left side of the driver's footwell (Figure 2). You will have to use a pair of needle nose pliers to remove the three plastic inserts that hold the panel in. Just pull 'em out. Then move the panel out of your way.

(FIGURE 2)

3) Unplug the CPU Wiring Connectors

Now you should be able to see the CPU. Its the rectangular box that has a big wiring harness plugged into the front of it. Unplug the 'big wiring harness' I just mentioned.

4) Remove the CPU Restraints

Now you're gonna need a 10mm socket and a short extension. A ratchet would be a good idea also (unless you have really strong fingers). At the top of the CPU is the nut that holds it in. Remove the nut.

5) Remove the CPU

Now you should be able to tilt the top of the CPU towards the passenger's side of the car while pulling upward on it. The CPU should pop right out. Notice how the protrusion on the bottom of the CPU fits into a little socket in the car. You'll need to realize how it fits when you put the CPU back in. There are also a couple more wiring harness connectors on the bottom of the CPU, unplug these also.

6) Rejoice

Now you have the CPU out of the car (Figure 3). Take it inside and plug up your soldering iron.

(FIGURE 3)

7) Start Taking it Apart

There are two small screws on the outside of the CPU case. One is on the bottom and the other is on the back. Remove these screws.

8) Remove the CPU Case

Now you will have to take a small screwdriver and pry the back lid off the CPU case. Also pry the bottom of the case off. You will have to be very careful and patient so that you don't break the case. After getting these covers off, you can remove the circuit boards from the case.

9) Resolder the Beastie

Take a close look at all the solder points on all three of the circuit boards. It would be wise to resolder all of them. However, if you're in a hurry you can just resolder the areas where the spade connectors for the wiring harness plugs are located. These are easy to recognize because of the copper spade connectors (Figure 4) on the component side of the board and the larger solder points (Figure 5) on the other side of the board. These solder points seem to be the main cause of trouble because they are under the most stress from the weight of the wiring harness bouncing around on them. They're almost always cracked and should get most of your attention.

(FIGURE 4) (FIGURE 5)

10) Put it Back Together

What is it all the shop manuals say? Oh yeah, installation is the reverse of removal. Just put everything back together and you should be in great shape.

3800 RPM Hesitation Fix (Dana Sullivan)

_____--_____
--------------------
| ------ | ------- |
--------------------
| ------ | ------- |
--------------------

This is supposed to look like the plug that connects to your boost sensor. Take the plug that has a brown (upper left) wire leading into it and run a ground from it to bare metal, try the radiator filler neck.

1) Locate the boost sensor on the front of the passenger's side strut tower. Note: There is a vacuum line running from the sensor to the side of the engine block.

2) Disconnect the 4­wire 'gang plug' from the sensor.

3) Locate the upper left wire. Refer to diagram.

4) Take a very small flathead screwdriver and insert it into the back of the plug on top of the wire. You should be able to raise a small flap of plastic allowing the brown wire with it's crimped connector still attached to be removed from the gang plug.

5) Take a 12" piece of thin gauge wire and solder one end to the connector where it is crimped around the brown wire.

6) Insert the crimped connector with the new wire attached back in the gang plug.

7) Loosen one of the bolts that holds the radiator cap housing to the filler neck. Strip ¾" of wire off the end of the ground wire your just soldered and wrap it around the loose bolt. Tighten bolt.

8) Plug gang plug back into boost sensor

EDITOR's NOTE: This fix is NOT guaranteed, it seems to have about a 50% chance of solving your problem. It does NOT work on my 1987 Sport, but others have had success with it. I personally do not think this is the cause of the problem. I believe, partially because it worsens in low temperatures, that it has to do with wear on one or more other components, or a programming error in the engine management computer. I happen to know of one 1987 GXL of a newer build date than mine which does not suffer from this problem. I believe that the problem may be caused by progressive failure of the exhaust system. I think that as the exhaust gets older and the front cats start to disintegrate into the main cat backpressure increases, causing the ports to open early or late. When I replaced the cats on my car with a downpipe and presilencer from MazdaTrix the problem promptly vanished.

Cold Solder points fix for the Clock/Idiot light (Tuck)

Start by placing the blade of a flathead screwdriver under the front lip of the plastic trim piece that is in front of the clock/idiot light unit. Pry it up and you will see two screws that hold the assembly in place, one on each side of the unit. Remove these screws and pull the clock unit out. The wires are tight but some slack can be pulled out from the inside of the dash. Unhook the clock/idiot light module. Remove a few screws from the back of the unit and carefully check and resolder all the solder connections on the socket for the plug. Resolder other stuff if you are feeling adventurous. Installation consists of plugging the unit back into the wiring harness, screwing it back in, and snapping the trim piece back over the unit. It is short and sweet. One important note, if you decide to resolder ALL of the solder points in the unit, be careful, there are a number of delicate components that can be killed with great ease by overheating, especially under that little black plastic thing.

Cold Solder points in the Logicon (Mike Mario)

I have repaired my logicon because my heater didn't maintain the correct temp. It would stay hot for a while and then the air mix motor would move the vent settings to the cold position. It would generally stay in that position. There is also another well known problem with the air mix adjust motors. They were manufactured with an inappropriate lubricant, which causes the motor to seize in low temperature environments. This can burn out the drive transistors in the logicon and possibly the motor itself. As a rule, if you took your car to the dealer because of logicon problems they replaced the air mix motor whether you liked or not.

My air mix motor was not the problem in my case, I even took the logicon out and tracked down the drive transistors and replace them to no avail.

To repair the logicon, all the solder joints need to be resoldered. There are 3 circuit boards in the logicon, a large main one, one behind the front panel switches and lights and one in a small separate box attached to the outside.

The problem in repairing the logicon is not the actual resoldering but rather getting the logicon out of the dash. It is fairly straightforward to take the logicon apart and get at the circuit boards.

To take the logicon out of the car, you first need to take the cover off the center cockpit console. First pop up the cover around the shifter, this is done by prying it up from the side toward the hand brake. This exposes 2 screws under the ash tray. Remove these screws and then remove two more screws at the very top of the trim panel.

The logicon is held in place with 4 screws two on each side. There are three connectors which need to be removed, two are connectors that plug into the back of the logicon and are reasonably easy to remove. The third is the big problem.

The third connector is at the end of an 18" cable which comes out from the logicon itself (why they did this I'll never figure out) it snakes up into the dash and disappears. It ends at a connector which is where the windshield meets the dash behind the clock/light module. There is a metal plate running the length of the dash along the window, you need to remove this plate to get at the connector.

To remove the plate (while minimizing the possibility of damaging the trim pieces) requires that you remove much of the trim around the front window. Start at the top and remove the side molding on one side of the window (you will need to remove the center trim piece on top of the window to do this easily). Now you can lift out the metal plate which contains the defrost vents and spans the dash from window pillar to window pillar. It is fastened down with a screw at the center which is covered by a small square plastic cover (which is extremely difficult to get off without breaking), and a number of strong snap in metal clips. After removing the screw the rest of the plate pops off. You will have to carefully maneuver the plate to get it out once it is unscrewed and unsnapped.

Now you can disconnect the connector and pull out the logicon. The cable going the connector is held in place by a metal strap in the middle of the dash, you may be able to get at the strap to bend it up from the opening made by the metal plate. I originally loosened the strap from below as I was removing the air mix motor.

Remove the logicon from the dash while carefully snaking the long cable out from behind the dash. Once you have done this it is a fairly straightforward process to disassemble the logicon and resolder the points inside. Almost all of them will be bad so plan on spending some time on this. You may want to source some replacement light bulbs for the lighting instruments in the faceplate (not the LED's in the sliders) so that you can replace them while the unit is out. When you are done, you may want to spray the boards with a clear enamel which is sold at electronics stores for sealing circuit boards. Reinstallation is much easier than getting it out, and once you have removed the unit once, subsequent removal is much easier.

NOTE: If your Logicon fries and you decide to pull it and fix it yourself, use a transistor checker. If the transistors appear to be fried then you might want to consider getting a new adjust motor before you replace/fix it. MazdaTrix stocks rebuilt logicons for $231 the part number is "LOGICON" and MazdaTrix can be reached at (310)­426­7960. I believe they can also sell you the bulbs inside the unit.

Intermittent operation of the passenger side speaker (Victor Bradley)

My 86 RX-7 had a Front right speaker that would go dead every now & then. When I whacked it with my palm, it would work for awhile, until I went over my next bump. Now I know what you're thinkin... cold solder joint, right? WRONG! Bad relay inside the speaker box. Here's how to fix it. Remove the speaker box, unplug it. (Make sure the radio is turned off first.) Open it up and look for a little black plastic box on the circuit board that's located just inside the rear cover just inside the box from where the main connector plug is. This little plastic box is a relay. The top pulls right off. Now you can watch the stupid thing turn on and off when you flex the circuit board. If it does as I've described, the fix is simple: just jam a short piece of a toothpick, or any other small insulator into the mechanism so that the relay points stay closed. This fixed it for me.

Catalytic converter shield fix (Tuck)

In my case, the front hangar has rusted out, and the shield was making a nice road kill scoop/gravel plow. Go to your local Trak Auto (or similar store, such as Auto Zone), and ask for a catalytic converter hangar. They sell them for a few bucks and they are perfectly adequate for the job. It took me all of 8 minutes to install two in my car (one on the front and one on the rear of my cat shield). The vast majority of this time was spent jacking the car up. All you have to do is wrap it around the cat and the shield, pull it tight and then screw it down. This is a much better fix than getting new parts from Mazda, as you have to buy a whole new catalytic converter to get the hangars ($900).

Clunk in rear suspension (Jay Harrell)

Replace the rear control links.

  • Notchy shifting into 3rd gear
  • This problem is caused by weak synchros in the Mazda 5 speed, it appears that the 5 speed used in the non turbo cars is approaching it's power handling limit. To completely solve this problem requires a transmission rebuild, but if you don't want to spend the money or the time, you can at least smooth things out a little bit by filling your transmission with RedLine synthetic lubricant. Some people have expressed concerns over using the RedLine MTL because it has a lower viscosity than the stock lubricant. It's your call as to whether you use RedLine synthetics or their MTL. If that doesn't do it, get your transmission rebuilt, be aware that parts costs in this case can easily exceed labor costs. You can contact RedLine at 1­800­624­7958.

    Broken outside door handles (Ken)

    Your best bet is to acquire a new handle from MazdaTrix, or from a junk yards and getting it painted to match by a competent auto body shop. Otherwise you may be able to fix the problem by opening up the door and using JBweld, or liquid weld, or whichever is your favorite metal repair chemical to fix any cracking in the metal of the handle frame.

    Rusted exterior window trim (Chuck Ortt)

    Snap off the plastic trim piece around the manual mirror adjust lever. Unscrew the mirror mounting screws. Pop out the original piece and replace with the Mazda replacement part (which is plastic). Put it all back together.

    Broken driver's side seat adjust lever

    This problem involves the plastic trim piece on the door side of the seat. This trim piece comes loose and can jam the adjust lever. The lever itself is a metal piece with a hole in it. There is a metal post on the seat adjust mechanism that is supposed to go into this hole. The retaining clip on the post fails and the lever pops off the post, causing the seat to continuously spring forward (and pushes the plastic mechanism cover out). If you remove the spring on the lever, then the seat will no longer pop forward, but the lever then has to be pushed back down manually to lock the seat in place. The only other solution is to replace the retaining clip and trim piece, or to replace the rails and adjust mechanism on the seat.

    Failing light switch:

    Replace the light switch assembly, this is due to a non­correctable mechanical failure in the switch. Please closely examine the plugs on the light switch, as this problem is usually accompanied by high voltages that melt the switch, plugs, and sometimes the wiring harness. If this is the case, replace the light switch wiring harness as well. The wiring harness and switch are available from MazdaTrix. The part number for the switch is "66­1700­FB01" and the harness is "66­1670­FB01". The switch is $225.30 and the harness is $65.75. MazdaTrix can be reached at (310)­426­7960. These parts can usually be acquired very cheaply at a junk yard. You can help prevent this problem from afflicting your car by disassembling the unit and resoldering everything inside it prior to failure.

    Failing Wiper Switch (Gary)

    First remove the binnacle that contains the switches, unplug the 3 large connectors, and take the unit in to the workbench for a close examination. Remove the wiper switch module by pulling the knobs off and unscrewing the 2 screws that secure the module to the plastic binnacle. Then lever off the white plastic cover over the circuit board (it is secured by tongues into the black plastic case). Then desolder the rows of pins that secure the circuit board to the three switches in the module and remove the circuit board. Now, lever the cover off the relay nearest the wiper switch end (careful, these relays are fragile inside) and examine the open contact, it may appear burnt. Dressed it up with some fine emery paper, gently push the outer fixed contact in a little to close the gap a fraction, and reassemble the whole mess. Viola! Your problem is solved.

    The tricky part is identifying the pins of the switches that need to be desoldered to get the PCB out. They are all along the "inside" edge, in two rows clustered in three groups (about 14 contacts in all). One of the wiper switch contacts is particularly difficult to desolder, as there are two pins shoved through the same hole. Use Dri-wick (solderwick) or similar, unless you have desoldering equipment at hand. Use only a hot enough iron to do the job, too much heat will cause the tracks to lift off.

    The switch is, of course, also available from MazdaTrix, and can be purchased very cheaply at a junk yard.

    Replacing worn out shift lever bushings (David Disney and Jamey Moss)

    The following info is for 86-88 Sevens, but the process is almost identical for the 1st gens, but some of the part numbers/bushings are different.

    First, obtain some new shifter bushings. I'd suggest getting them from MazdaTrix, as your local dealer will charge you 2-3 times more, depending on the day of the week... and they won't have them in stock either. Anyway, the MazdaTrix part numbers are as follows:

    99-1780-M505 ~$6.50

    17-4810-8AF1 ~$6.50

    1-800-426-TRIX

    Next, you have to get to the old bushings:

  • 1) There is a locknut just below the shifter knob. Take an adjustable wrench and turn it clockwise. The knob should now be lose and you can remove it and the locknut.
  • 2) CAREFULLY pop off the shifter cover panel. It contains the leather boot and pops straight up as one piece. If you are not careful you will break the tabs off the panel. Also, do not pull on the leather boot... bad idea.
  • 3) Now you can take a 10mm socket and a short extension and remove the 3 bolts that hold the shifter to the transmission. You may have to fish around in the myriad of rubber boots to get at them, but have patience and you'll be ok. After removing the 3 bolts, apply moderate upward pressure to the shifter lever. It is held in to its socket by a spring, so you may have to wiggle it a bit while you pull up on it.
  • 4) So, now you should see the plastic bushings (or what's left of them). I would suggest fishing any chunks of old bushing out of the shifter housing.
  • 5) Now you can look at the old bushing setup and get a good idea how the new ones should go. Its something like this: On the bottom of the shifter 'ball' there should be (going from bottom up) a spring washer, possibly another thin washer, and finally the plastic cup that the 'ball' sits it. On the top of the 'ball' they go in the opposite order. The tricky part is the top. You'll have to _carefully_ remove the rubber boot so that you can slide the bushing down over the shifter lever. I find that some Windex helps grease things up.
  • 6) Assembly is the reverse of installation (duh, where have I heard that before?). When you put the shifter back in, be sure that the little notches in the 'ball' cups (no laughing!) line up with the slot in the shifter ball and the little knob in the shifter housing.
  • 7) Put everything back together and you're done!
    1. NOTE! You won't use all of the stuff that comes in the previously listed parts kits. Mazda apparently decided not to make a single 86-88 bushing kit, so you have to 'make your own' from these two kits. The parts to use are as follows:
    2. Keep the blue bushing, the white bushing, one spring (the round metal piece with clips), and one gasket. Next, put the blue bushing on over the shifter with the rounded side of the bushing next to the large ball part of the shifter. Clip the spring to the white bushing (it only goes on one way), then put the white bushing, spring-side down, into the hole where the shifter goes, aligning the grooved part of the bushing with the aligning pin in the hole.

    Section III

    Tuning and Performance

    Ignition Timing(Dave Henning)

    I did the timing on my '86 sport recently. I didn't use a tachometer for 2 reasons:

    1) I could not just go buy a tachometer and expect it to give a proper reading since they are all set for cylinder types of engines.

    2) The tachometer on the dash seems to work just fine.

    The timing only requires a light with the inductive coil on it. It should state this on the box and can be purchased at WalMart or store of your choice for <$30. Don't get the expensive ones with the dials they aren't worth it.

    Hook the inductive coil around the leading wire to the front rotor. Then connect the other wires to the battery and ground. Loosen the bolt to the crank angle sensor. It is brass so be careful not to strip it. Do not remove the screws on the sensor plate, it does no good.

    Turn on the engine and let it warm up to idle. Pull the trigger of the light and point at the pulley at the base of the crank angle sensor. There are 2 marks, yellow for leading and red for trailing. They may be difficult to distinguish. The timing light should be hooked close to the coil and not the spark plug.

    There is a pin above the pulley to match the yellow mark to. If you cannot tell which color is which just turn the crank angle sensor (it pivots after you loosen that bolt) and get one of the marks set with the pin.

    Disconnect the inductive coil and re-connect it to the trailing wire for the front rotor. Point the gun at the pulley again and squeeze the trigger. If there is a mark (should be red but maybe can't tell) lined up with the pin then you are done and should shut off the engine and tighten the bolt to the crank angle sensor. If the mark is _way_ off then you confused the colors and should redo the leading timing until the other mark is lined up properly, then redo the trailing timing.

    If you cannot reconcile the marks to both line up properly, make sure you are using the proper wires. They are marked L1 and T1. If they still do not line up then ask more people on the list for advanced help. BE CAREFUL!!!! While adjusting the sensor the engine is at operating temps. This may cause you to want to use a rag to turn it and not burn your hand. However, the fan and some belts are in very tight proximity and could hurt you if you don't take care.

    The Haynes manual pictures should point out the sensor. If you aren't sure where it is, it is on the driver's side and behind where the a/c and power steering (if you have it) pumps are located. It has a black cover with 2 screws on top. It is about 2-3" in diameter on top and smaller as it joins the engine. Good Luck, it takes about 1/2 hour even while you are learning. It took me more time to go buy the light.

    Making a Throttle Position Sensor Test Lamp(Dana Sullivan)

    You can make a test light yourself fairly easily. Take two turn signal bulbs or similar type lights and solder a piece of wire between the two cans of the bulbs. Take another length of wire and solder one end to one can. This wire is your common ground wire, this will attach to the Black w/white stripe wire (ground) on the gang plug.

    There should be 2 wires running out of the two remaining connectors. Solder a piece of wire to the + terminal of each light bulb and run one each to the two remaining connectors.

    Throttle Position Sensor Adjustment (Glenn Heidel)

    1) Warm up the engine, then stop it.

    2) Connect the checker lamp to the check connector (green).

    3) Turn the ignition switch on and check whether one of the lamp illuminates.

    4) If both lamps illuminate or if neither does, turn the throttle sensor adjust screw until one of the lamps illuminates.

    a) If both lamps illuminate turn the adjust screw clockwise.

    b) If both lamps do not illuminate turn the adjust screw counterclockwise.

    I'd just like to add that I found the best results by turning the screw counter-clockwise until I obtained condition 4)a) above (both lit) then I turned the screw clockwise until one light went out + 1/8 turn of the screw. This assures the throttle is as close to actually closed as possible when the sensor indicates that condition to the computer. (Thus giving you the smoothest transition on/off idle.)

    Sensor Diagram:

    ----

    | |(A) (A) = Top

    | -- | (B) = Bottom Right

    - - (C) = Bottom Left

    | |

    (C)| | | |(B)

    | |

    --------

    Note you can also use two DC volt meters; connect the positive leads of both volt meters to terminal A. Connect the negative terminal of one meter to C and the negative of the other to B. If you have basic point type probes on your volt meters, they will slide nicely into the connector and you don't need to build the test lamps. Put them into the position for measuring DC 12 volts (...or more) and away you go.

    Adding an Aftermarket Alarm system (Shane Callaghan)

    For those of you that have the Mazda security system, installing a quality aftermarket system is a simple job and effective protection. Disclaimer: The following is based on the factory system in my '88 Turbo, and may not be directly transferable to other models/years; confirm all connections, and don't call me if you fry something!

    A few words on selecting an alarm:

    There are many aftermarket alarm manufacturers; I won't presume to tell you which to choose, but a reasonably secure system requires some basic features. Consider the available security and convenience features, and pick one that meets your needs. Some features can be easily added, so when selecting an alarm, concentrate on the things you can't add (extra transmitter channels, pre-warning circuit, code jumping, anti-carjacking, etc.). One thing to consider: since 2nd gens do not have a lock motor in the driver's door, a power lock interface requires an external motor.

    When you have chosen your alarm, much of the basic wiring can be done from the factory harness to the Mazda alarm. I would recommend replacing the Mazda unit with the aftermarket alarm - I ran parallel systems for awhile, but if the aftermarket system is designed and installed properly, the factory system is not necessary; it will be more likely to give you problems than protection.

    Before tearing out the factory box, think about where you want the valet switch, LED, and glass break microphone. I find the LED works just fine in the blank panel next to the factory light (unless you have a convertible), which is also a good place for the glass break microphone, or you could use the factory light itself. The advantage to using a different LED is that a thief who knows the car will realize it has an aftermarket alarm, and may look elsewhere. If you have a convertible, you could replace the factory light with a blank panel (about $2 from Mazda). As for the valet switch, look for a place that is relatively easy to access, but not easy for a thief to find (although the valet switch will not compromise the alarm on most systems). There are some things about my system that I won't reveal - this is secret #1. Route both wires to the glove box area when both are mounted.

    The factory alarm brain is screwed to the back of the panel beneath the glove box (which also houses 4" speaker and air vent). First, remove the glove box; there are 7 screws, three along the hinge, one on each side, and two on the catch. Pull the box straight out, reach behind and twist the light to remove. Remove the 5 screws holding the lower panel in place, and slide it towards the floor to remove. There are two air ducts attached to the panel; remove carefully to avoid cracking the plastic. The alarm brain is the steel box mounted to the left of the panel. Unplug the alarm connector (next to the recirc. air intake) and the speaker connector (if equipped), and remove the panel.

    If you don't anticipate reinstalling the factory alarm (or if you don't mind reconnecting the cables), cut the harness close to the alarm box. This will allow you to wire the free ends to the aftermarket harness, and plug directly into the factory harness. Remove the factory alarm from the panel, and find a place to mount the aftermarket box. If it is small enough, it will attach (using wire ties) to the wiring harnesses and brackets at the top of the dash, just behind the windshield. This way, if a thief knows the car and gets this far, he won't find the box in the usual place. Make sure any DIP switches are set correctly, and all harnesses are connected to the brain before mounting it permanently. You will want to complete the connections and test everything before mounting permanently, so just hang it approximately where it will go for now.

    Next step is installing the siren. You will want a location that provides good volume, keeps the siren where it won't gather water, and is not easily visible or accessible from under the hood (secret #2). Route the wire in or along the factory harnesses so that it is not visible. The siren wire should come through the firewall at the same location as the factory harness; I don't remember how difficult this was on the RX-7, but it is usually one of the least enjoyable parts of the job. If you don't intend to use the auxiliary alarm horn, you could use that wire (there is a separate horn for the alarm in the centre of the nose, to the left of the relays - you can also use the main horn for the alarm). If necessary, run the siren wire from the inside of the firewall along the dash to the glove box area.

    You may want to add an interior piezo siren, or pain generator. This can be wired in parallel with the main siren, and will make it very unpleasant to be inside the car while the alarm is sounding. Mount the siren so it is loud, but not easily disabled by a thief (secret #3).

    Now you can complete the wiring. Using the factory harness, and assuming your alarm has the appropriate features, you can easily wire a starter disable, flashing headlights (through the lenses) and hazard lights, pulsing horn, and gain access to the trigger for the doors, hood, and hatch. A flashing light output from your alarm is required for the lights and horn, but the relays are already in place. Wire your alarm as follows (colour diagram in Word) Be sure to use diodes to isolate current from the door, hood, and hatch triggers:

    Color Code:


    B Black L Blue O Orange

    Br Brown W White R Red

    G Green LG Light Green Y Yellow



    If you intend to use a fuel cut relay (highly recommended), you can tap into the factory harness beside the dead pedal, next to the fuse box. The bottom of the three plugs contains the fuel pump wires. There are two blue wires which join shortly after the plug; you need to cut and switch both - either one will run the fuel pump. Wire the relay as follows:



    You can also add additional flashing lights (brake, dome), additional siren(s), remote window roll-up and sunroof close, remote start, etc.

    Adding Cruise Control (Ken)

    To install cruise where there is none, you really only need three things.

  • 1. instrument panel switch
    1. actuator motor
    2. control unit

    The pieces I speak of are Mazda originals, taken from a junkyard, not new parts or some aftermarket contraption. l of the wiring for these parts exists on the car already. It is a simple "plug and play" procedure to hook everything up.

    The actuator is located on top of the cold-start-assist reservoir. When you get all the parts from the junkyard, be sure to get the bracket that mounts the actuator to the firewall (non-cruise equipped cars do not have the bracket). I tapped a capped-off vacuum port above the exhaust manifold as a source for the actuator (after all the scrounging, I have come to believe that turbo cars use an all-electric actuator). Manifold vacuum is what pulls on the throttle cable to manipulate the throttle. The logic unit directs the actuator in this operation. Four wires attach to the actuator, in a plug which is already there and waiting for installation.

    The control unit is attached to the kick panel next to the "cpu." (close to the "dead" pedal), two nuts are needed to hold it in place on the studs which are already there. A thirteen-wire connector is plugged in to the control unit. One of these wires goes to a speed sensor on the back of the speedometer, but it is already hooked up at that end.

    The switch goes in the pod surrounding the gauges, next to the wiper switch (where the "blank" spot is). Contrary to what I have heard others say on the net, you DO NOT have to remove the steering wheel to get this piece off. Again, the wires are there and waiting.

    I took switches for the brake and clutch pedals, although I discovered after installation that my brake switch is already hooked up. I haven't looked into the clutch switch yet (and doubt if I will), no one that drives my car is crazy enough to push in the clutch with the cruise on. :-)

    I learned more about the way the control unit operates the actuator; anyone interested can drop me a line. All the parts cost me a total of $26.00 (!) with the exception of a new throttle cable I had to buy from Mazda ($31.00) because the people that pulled the motor from the RX-7 in the junkyard cut the cable.

    Removing the turbo unit from a Turbo II (Rob Rike)

  • 1. Remove Intercooler
  • 2. Remove Air Box
  • 3. Remove Air pump
  • 4. Go ahead and disconnect lower radiator hose to drain radiator and get hose out of the way for now.
  • 5. Remove the BAC valve and move it out of the way .
  • 6. Remove the Air Control Valve and be careful not to lose the reed valve looking thing contained in it. If it does fall off, when reinstalling the small round piece goes into the engine side.
  • 7. Jack the car up and get down to the dirty task of removing the heat shields. (DISCLAIMER::: They are a royal pain in the ass and I cut or broke the majority of mine. The heat shield around the turbo will not come off until the pre-converter is removed and you can slide it out from underneath the car.
  • 8. Unhook the split air pipe running from the Main Cat to the engine. It is secured to the engine by two nuts.
  • 9. I went ahead and disconnected the middle exhaust system mounts and the rear ones since the pre-converter has to come off next. It will give you extra room to wedge it out.
  • 10. Once the mounts are loose, take a 17mm deep well socket and remove the nuts connecting the pre-cat to the exhaust pipe.
  • 11. Now it is time to remove the pre-cat. It is held in place by 3 bolts running to the Turbo's turbine housing. With the heat shields off, one is accessible from the top of the engine with a 14mm wrench (not enough room for a socket). The other 2 are accessible from under the engine. With one, I used some 14mm socket and extension combination and got to it fairly easy. The last one I used the same combination along with every extension bar I had plus a universal joint right behind the socket. I went up along the tranny tunnel at an angle and worked the socket onto it. Saves much frustration and scraped knuckles.
  • 12. Make sure you have unplugged the O2 sensor and prepare to lower the cat. It is heavier than it looks so don't drop it on your head.
  • 13. Now it is time to disconnect the assorted coolant and oil lines to the turbo.
  • a. (TIP- The tire iron in the back of the car is the perfect size to fit the nut on the coolant pipe flange bolt) Disconnect the flange bolt and then disconnect the 2 nuts that secure the pipe to the engine.
  • b. Disconnect the oil line fitting with a 17 mm wrench and a pair of vise grips on the other bolt.
  • c. Disconnect the oil drain line. It is a braided hose with 2 10mm bolts securing it to the engine mounting.
  • d. Finally, disconnect the coolant return line. It is a rubber hose running into what looks to be the water pump. It is a 90 degree hose and now is a good time to replace it.
  • 14. With everything presumably loose or disconnected, it is time to remove the turbo. It is held in place with 4 14mm bolts to the exhaust manifold. A combination of 14mm socket and extension bars with get the right to bolts from above the car and then crawl under and remove the left two with a wrench.
  • 15. You should now be able to lift the turbo up and out of the engine. It takes some twisting and wedging but trust me, that is the only way that bastard is coming out of there.
  • Installing the Turbo unit in a Turbo II (Rob Rike)

  • 1. Sit the turbo back on top of the exhaust housing and make sure that the compressor intake pipe lines up and does not hit the engine anywhere, etc. Assuming all is correct, go ahead and put the two right hand side bolts of the turbo on and finger tighten them. Then get under the car and finger tighten the left two on and go ahead and snug down the lower left one. Get back up top and snug down the upper right one and then back under for the upper left one. You guessed it, back up to the top and tighten the lower right one and that baby is back on.
  • 2. Now is a good time to go under the car and insert the main heat shield up in its approximate position. It is almost impossible to do from above the car.
  • 3. Go ahead and put the pre-cat back on the car and bolt it down tight.
  • 4. Rehook all of the hoses to the turbo that you disconnected. When reconnecting the coolant line that faces the passenger side of the car, make sure you connect the end that goes to the engine first!!!!! (Trust me here, I busted the bolts off the intake manifold end while trying to torque these down to stop a leak. The flange bolt is a lot stronger than the 6.0 X 1.0 mm bolt studs. If for some reason you do break one along the way, you should be able to get it out with a pair of vise grips, it is not very tight. Replace it with a 6.0 X 1.0 bolt of appropriate length)
  • 5. Go ahead and connect the oil lines and other fittings to the turbo (I used a little liquid Teflon tape on the oil pipe fitting)

    6. Re-connect the hoses that you removed and go ahead and refill and air bleed the radiator.

    7. Go underneath, reconnect the exhaust pipe to the pre-cat and re-attach all of the system hangars.

    8. Double check all of your fittings and make sure all hoses are tight. Watch that coolant pipe going to the turbo for leaks.

    9. Since the Turbo has probably been removed to be rebuilt, I would go ahead and remove the EGI fuse and crank the engine over for several seconds to get some oil into the turbo bearings. You don't want to start it up and have that fast idle thing kick it up to 3,000 rpm's on dry bearings. For that matter, when you do start it you may want to leave it in first to prevent the fast idle.

    10. Once the engine starts to warm up a bit the turbo will probably start to smoke under the hood. I am told this is normal as new oil used during rebuilding burns off the housings and as the solvents heat up and burn off. Just keep an eye out for oil and coolant leaks and let it idle for about 15 minutes before driving it. This way you can be sure the bearings have plenty of oil.

    Aftermarket Performance

    Non-Turbo Performance Modifications-Street Legal

    Exhaust

    86-88

    Racing Beat "PowerPulse" high performance muffler system, >5 hp.

    HKS Sport Exhaust, 8hp

    Mariah (Design Energy)-HKS "Cat-Back" Exhaust, 15% increase=21.9hp

    MazdaTrix Exhaust, "Noticeable" (HKS?)

    89-92

    Racing Beat "PowerPulse" high performance muffler system, >5hp.

    HKS Sport Exhaust, 8hp

    Mariah (Design Energy) HKS "Cat-Back" Exhaust, 15% increase=24hp

    MazdaTrix Exhaust, "Noticeable" (HKS?)

    Intake

    86-92

    HKS "PowerFlow", 9hp

    Mariah (Design Energy) Nelson/Paxton Supercharger, 50% increase=73hp (86-88)/80hp (89-92)

    Other

    Mariah (Design Energy) Electric fan/shroud package, up to 12hp.

    Non-Turbo Performance Modifications-Off Road Only

    Exhaust

    MazdaTrix Dual PreSilencer Exhaust, ~30@Wheel horsepower

    Racing Beat PowerPulse Presilencer (replaces Catalytic Converters), 18hp (with stock cat-back exhaust)

    Intake

    Cartech/Mariah turbo Pkg., up to 129hp (86-88)/up to 115hp (89-92)

    Mikuni 44mm Side Draft carburetor

    Weber 48mm/51mm Down Draft carburetor

    MazdaTrix supercharger Kit, up to 154hp

    Second Generation RX-7 Turbo II Performance Upgrades (Trey Cobb)

    The layout of this list is as follows: Upgrades are ordered roughly in the order that you should do you upgrades. All upgrades can be done seperately but often, one part will not do much for you unless you install the next part that complements it. These groups of parts are commonly refered to as "Stages". HKS has probably the best organization of stages and even if you don't use all their parts, you can get the general idea of how you should upgrade.

    A few things everyone must think of when they want to upgrade their RX-7 is:

  • 1) How much money are you willing to spend?
  • 2) What will you sacrifice first: price, reliablity or power?
  • 3) How street drivable do you want the car?
  • 4) Street Legal Power or Not?
  • 5) Could you not spend you money FIXING the car instead?
  • Remember, these part's manufactures are businesses, and a business's main function is to make money so they will tell you close to anything for you to buy their product. Luckily there are some reputable companies out there, and the RX-7 producers are on the most part reputable.

    Now, on to the parts. After talking hours with many different RX-7 mechanics, this is a general "Stage" list for upgrading it. This takes into consideration that your car is basically in "as-new" Stock condition. This means that everything from the clutch to the fuel injectors are working close to how they did off the show-room floor. If anything is in question, inspect and/or replace it.

    Stages for Upgrading

    (Ryan Scott)

  • 1) Exhaust
  • 2) Intake
  • 3) ECU / Fuel Systems
  • 4) Intercooler
  • Instead of the generic, "do this to support x amount of boost", I going to inject my personal opinion and findings here. I own an '87 Turbo that began as a slightly modified car, and has transformed into a 450 horsepower monster. So I know what is involved with all stages of modifications. The same philosophy I learned in tinkering with my Turbo, can also apply to your non-turbo.

    The first step, opening up the exhaust will yeild the highest percentage gain on Mazda rotaries. This is due to Mazda making the exhaust systems very restrictive. This helped quiet the harsh rotary exhaust noise, and to keep the emissions under control. There are countless exhaust systems to choose from. But you must consider whether or not the car will need to meet emissions levels testing or not. If you car will likely have to take an emissions test, then keep your main catalytic convertor. The pre-cat can still be gotten rid of, since it only helps for emissions during the car's warmup. If you don't have to take emission, then that opens things up a lot. On a turbo car, the bigger the better. Backpressure only hurts on a turbo, whereas on a non-turbo, you need to keep some backpressure to ensure low end torque. Also on a non-turbo, the 6 ports will not open correctly without some backpressure. Mufflers supply some backpressure, but the majority of it is supplied by the restrictive catalytic convertors. Consider these factors when choosing an exhaust system.

    Next is the intake system. This is another big source of restriction. Basically, the engine is just a big air pump. The more efficiently it can pump air, the more power it can make. By removing the stock airbox, and replacing it with a cone style air intake, you are removing a big restriction, and allowing the engine to pump more air. One thing to consider, is that even though the engine will pump more air with one of these filters, the air will be hotter than before. This is due to the air coming from under the hood, instead of from outside. Hot air makes less power because it is less dense. It is also more damaging to the engine obviously, because more heat increases the chance of detonation - the number one cause of blown engines in rotary engines. The way to combat this is to find a way to get cold outside air into your cone style filter. There is not 'bolt-on' way to do this, instead it takes some thought. You can cut a hole in the front firewall, under the right headlight. Or even mount the filter ahead of the front firewall, like I did. This however, takes some fabrication. But the benefits are many and well worth the work. Also in the intake system, you could consider your carbuerator and or turbocharger/supercharger. This is something that is beyond the scope of a FAQ. However, if you are consider upgrading either of these, e-mail me with your questions. I'll do the best I can to help.

    Possibly the source of the most opinions and speculation is what to do to modify the fuel and ignition systems. There are bolt on systems to control fuel such as the HKS F-CON and the Field SFC. These are commonly known as 'piggy-back' computers because the essentially just suppliment the stock ECU. However, these systems are very limited in scope. For someone who is running the stock turbo, or in a non-turbo application, these sytems can work very well. But for someone who has a large aftermarket turbo like my T04B, or someone with a supercharger, these just don't cut it. For these applications, you need to look at systems like the Wolf 3D or the Haltech. Wolf EMS and Haltech make what is called a 'stand-alone' system. They replace all the stock ECU and control all engine functions with their own software and coding. The main benefit to stand-alone computers is their adjustability. When you start getting wild with your modifications, such as going for 350 horsepower or more, you need this amount of adjustability. Along with this flexability also comes complexity. Stand-alone systems are not easy to hook up and tune, they take a fair amount of knowledge. But if you are comfortable with taking on this task, or have someone near you who is, I highly reccomend going this route. You will always be able to adjust for any further modifications or changes to the car, and will extract maximum horsepower.

    1) Exhaust

    Company Name Type of System Claimed HP Cost CA Legal
    HKS Cat-Back 50mm +18HP? 464.95 Yes
    HKS Cat-Back 60mm 519.95 Yes
    Racing Beat Turbo Back +58HP 560.00 No
    Trust Cat-Back 50mm 547.20 Yes
    Trust Cat-Back 60mm 547.20 Yes
    Trust Cat-Back 70mm +40HP? 585.20 Yes
    Turbo Tuf Cat-Back +30HP 709.00 Yes

    2) Intake

    Company Name Type of System Claimed HP Cost Type
    AEM TurboFlo ~+15HP 163.00 Cloth
    K&N (86-92) FilterCharger ~5HP 48.54 Cloth
    HKS (86-88) PowerFlow +10-15HP 173.74 Foam
    HKS (89-92) PowerFlow +10-15HP 158.97 Foam
    HKS (86-88) Super PowerFlow
    HKS (89-92) Super PowerFlow
    Trust Airnix +15HP Foam

    3) Fuel Controller

    Company Name Type of System Years Cost CA Legal
    Electromotive TEC-II 86-92 1300.00 Yes
    HKS PFC F-Con 86-92 895.95 Yes
    Motec 86-92 ~2000.00+ No
    PROM [ECU] Reprogramming 86-92 ~700.00 Yes
    Trust Rebic II 86-92 Yes
    Racing Beat Fuel Cut Switch 86-88 91.50 Yes
    Racing Beat Fuel Cut Switch 89-92 96.00 Yes

    4) Intercooler

    Company Name Type of System Claimed HP Cost CA Legal
    CarTech Dual Cooled Yes
    HKS (86-88) Front Mount 1573.83 Yes
    HKS (89-92) Front Mount 1573.83 Yes
    Tri-Point Front Mount 1050.00 Yes
    Trust Front Mount Yes

    5) Turbo Upgrades

    Company Name Type of System Claimed HP Cost CA Legal
    Trust Yes
    HKS
    CarTech RotoMaster
    Blitz
    Turbonetics

    6) Fuel Pump
    Company Name Type of System Gal/Hr. Cost CA Legal
    Mazda Cosmo Pump 389.00
    Trust
    Holley 255 lph pump 199.00
    Walbro 255 lph pump 140.00

    7) Fuel Injectors
    Company Name Cost CA Legal
    Turbo Performance
    RC Engineering

    8) Turbo Boost Controllers

    Company Name Type of System Gauge Inc. Cost CA Legal
    HKS EVC I NO 655.58 Yes
    Racing Beat Manual Boost YES 242.19 Yes
    Trust TVVC NO Yes
    Turbonetics Manual Boost NO 60.00 YES



    9) Ignition Components

    Company Name Type of System Notes Cost CA Legal
    NGK BUR6EQ (L) Hot 11.32 Yes
    NGK BUR8EQ (T) Hot 11.32 Yes
    NGK BUR6EQP (L) Hot,Plat. 18.42 Yes
    NGK BUR8EQP (T) Hot,Plat. 18.43 Yes
    NGK BUR7EQ (L) Cold 7.55 Yes
    NGK BUR9EQ (T) Cold 7.55 Yes
    NGK BUR7EQP (L) Cold,Plat. 13.17 Yes
    NGK BUR9EQP (T) Cold,Plat. 13.17 Yes
    Magnacor 8.5mm Wires Street 52.56 Yes
    Magnacor 10mm Wires Street 62.14 Yes
    Ultra Ign. 8mm Sil. Wires Street 86.08 Yes
    Ultra Ign 8mm Sil. Wires Race 75.16 Yes
    Crane HI-6 Ignition Amplifier 160.00 Yes

    10) Blow Off Valves

    Company Name Type of System Part # Cost CA Legal
    GReddy Type "S" Kit BVS-11007 215.00 Yes
    HKS Super Sequential 225.00 Yes
    Blitz Super Sound 195.00 Yes

    11) Clutch/Pressure Plate Combos
    Company Name Name of System Years Type Cost
    CenterForce Dual Friction 86-88 Both 496.02
    CenterForce Dual Friction 89-92 Both 461.15
    Turbo Clutch Kevlar 86-92 Both 399.02
    Turbo Clutch Carbonite 86-92 Both 419.00
    Racing Beat Street/Strip 86-92 Disc 105.20
    Racing Beat Street/Strip 86-92 Plate 280.00
    Racing Beat Street Race 86-92 Disc 113.00
    Racing Beat Full Race 86-92 Disc 89.00

    12) Flywheels

    CompanyName TypeofSystem Weight Years Cost
    RacingBeat Steel 18lbs 86-88 372.00
    RacingBeat Steel 18lbs 89-92 372.00
    TriPoint Aluminum ?? 86-92

    Please forward all comments, info, and corrections to:

    Ryan Scott
    12216 Spanish Trace Dr.
    St Louis, MO 63043

    Or E-Mail Ryan Scott

    A Few random notes:

    Turbo II production began in 86 but there are no 86 modeled cars, production ended in 91 but '91s were resold through 92 before the 3rd gen. Debuted. The only MAIN difference is between the years 88-89. If you own a 87 Turbo II, you can NOT use a part stated as being for a 89-92 vehicle unless otherwise stated. The same holds true visa versa.

    Section IV

    Miscellaneous Ramblings

    What is the deal with using synthetic oils in a rotary engine?

    This seems to come up a lot. Net wisdom preaches that you shouldn't use a synthetic oil in your rotary is because the engine sprays some oil in with the fuel to lubricate the apex seals on the rotors. Synthetic oils do not combust fully, which leaves deposits between the seal and the rotor itself. This buildup prevents the seal from sliding like it should, which leads to premature seal wear and engine failure. Many people will tell you that they use synthetics all the time in their rotary and that it doesn't cause any problems at all. The fact of the matter is that synthetics don't make your engine run faster or better. They cost more, and you really should change them just as often. It is cheaper to run conventional oil. Synthetics are great in the differential and the transmission, just make sure that the differential fluid you use is the proper type or it will cause problems with some types of limited slip differentials. Use the RedLine oil in the transmission and the differential.

    Now for brutal honesty. If you read through the catalogs from some of the engine tuners out there, like Racing Beat and MazdaTrix, you will see that they either recommend, or are careful not to condemn, the use of synthetics in the engine. While a new engine should always be broken in on a high quality mineral oil (Castrol GTX is the oil of choice according to net wisdom), in the long run, using a high quality synthetic oil, like Redline or Amsoil can help keep temperatures and wear down in the engine. Some claim that it can also significantly reduce carbon deposits on the rotors housings. Mazda Competition Parts recommends the use of synthetic oils in rotary engines once they are properly broken in.

    For what it's worth, I use Castrol GTX in my car, and so far the oil has come out close to the same golden amber color that it went in.

    What is the least expensive way to speed up my RX-7

    First, try opening up the exhaust. Mazda made the stock exhaust small and restrictive in an effort to contain some of the rotary engines rather noxious emissions. Of course, this means that an aftermarket exhaust will free up lots of lost power. Especially for turbo models. Removing the catalytic converters alone can take close to a second off of 1/4 mile times. Other than exhaust, the cheapest way to speed up your 7 is to learn how to drive. Autocross regularly and try to take a performance driving school. Also, there are many books that can teach you the basics of high performance driving...read one.

    How big can my wheels get?

    With the stock offset, you can run up to 225/55 r16's in front, and 245/55 r16's in back. The car was available with 14, 15, and 16" wheels. The 16" wheels of off a Turbo II look great on a non­turbo, as well as being fairly inexpensive used. And as a small note, I thought I'd mention that if you have a white non-turbo RX-7, and you can find them, get the white wheels from a 10th anniversary edition RX-7, this is what I have on my car it really makes the car stand out.

    Tire Size Sidewalls Rim Total Variance Circum. Deviation
    205-55-16 22.55 40.64 63.19 0 198.52 0
    215-50-16 21.50 40.64 62.14 -1.05 195.22 -1.66%
    225-50-16 22.50 40.64 63.14 -0.05 198.36 -0.08%
    235-50-16 23.50 40.64 64.14 +0.95 201.50 +1.50%
    245-45-16 22.05 40.64 62.69 -0.50 196.95 -0.79%
    205-50-17 20.50 43.18 63.68 +0.49 200.06 +0.78%
    205-45-17 18.45 43.18 61.63 -1.56 193.62 -2.47%
    215-45-17 19.35 43.18 62.53 -0.66 196.44 -1.05%
    225-45-17 20.25 43.18 63.43 +0.24 199.27 +0.38%
    235-40-17 18.80 43.18 61.98 -1.21 194.72 -1.91%
    245-40-17 19.60 43.18 62.78 -0.41 197.23 -0.65%
    255-40-17 20.40 43.18 63.58 +0.39 199.74 +0.61%
    265-40-17 21.20 43.18 64.38 +1.19 202.26 +1.88%


    How to Clean up your paint job

    Start by purchasing the following products:

    Start off by hosing the car with the Bug/Tar remover, this will help remove the old wax and any crud that may be on the car. If possible, get aggressive and get the door hinge area cleaned as well as possible, then hit the moving parts with spray-on white lithium grease. Once you have finished with the bug and tar remover, wash the car with a good dishwashing liquid, like Palmolive, this will make sure that all of the old wax is off the car. Then use the Zymol (if Zymol is not available, use the Meguiar's gel soap, the Mother's soap is crap) car wash (plus add one tablespoon of olive oil with the soap before adding water) and wash carefully and thoroughly. Dry the car completely (do NOT use anything but towels or synthetic chamois, never use a "genuine leather chamois").

    Once you are done washing the car, get out a clean cloth and the Mother's precleaner. Use this aggressively on any area where the paint is rough. It is an extremely light abrasive, so the possibility of damaging your paint is minimal, it will take a long time to deal with really rough areas though, so be prepared to take your time and invest some serious elbow grease if you want top notch results. If a section of paint is extremely bad, you might want to try a traditional rubbing compound, but these can cause serious damage to your paint, so be careful if you do. Multiple applications of the precleaner may be necessary for optimal results.

    After the pre-wax cleaner, use the Mother's sealer and glaze. This makes the paint a bit slicker, hides swirls, and deepens the luster, it does not take much to do an entire RX-7. Finish the job off with a coat of Mother's carnuba wax. Be careful not to get the wax, precleaner, or glaze on rubber trim parts.

    Once you have finished with the paint, it is time to move onto the rubber. Start off by hitting the wheels with a generous application of Armor all Quicksilver. Let it sit according to directions and hose off. Some of the smaller areas may require direct intervention in the form of a rag. Be careful when applying or spraying it off to keep it from getting on your freshly waxed car. Hit the tires with the tire foam according to the directions, and then get aggressive with the Back to Black on the rubber trim. To deal with the interior of the car you may need some other chemicals, like leather or upholstery cleaner. Generally any chemical which does not say it is environmentally correct will work well. I specifically mention the low gloss Armor All because the high gloss will cause noticeable reflections on the windshield while driving If you use it on the top of the dash. Both the Armor All and the back to Black are excellent on interior components as well. The back to black is better on more worn surfaces, while the Armor All can make things look a little shinier.

    Use all the chemicals according to directions written on them, and take your time going from one step to another. While following this process you can burn most of an afternoon without half trying.

    Cooling System Flush and Fill (Shane Callaghan)

    There is an easy, clean and effective way to completely flush and fill your cooling system. Prestone makes a nice flush and fill kit (~CDN$10) that requires nothing but a garden hose. It includes a drain hose and container, funnel adapter and hose clamps. Disconnect the top rad hose at the water pump housing (kit says cut it - don't), attach the drain hose to the pump outlet and insert in the container. Insert the funnel adapter into the open hose going to the rad, and fill with water. Bring the engine up to temperature and turn on the heater. When the thermostat opens, the old coolant is pumped into the container, and the water is drawn into the system. Keep the funnel full to avoid drawing air into the system; it helps to have two people - one to keep the funnel full, and one to make sure the drain hose stays where it is supposed to. When the drained fluid is clear, you can start adding coolant to the funnel. I wait a couple of minutes after the water is clear to make sure the system is well flushed. Add a full jug of Prestone (about a 50/50 mix), and shut the car off. Replace the hose, top off the rad and you're done. Easier and more effective than just draining the rad.

    The TSB Title list

    Year: 1986

    Make: Mazda

    Model: RX-7

    Engine: 2RTR-1308cc 80

    JUN 94 1. PARTIAL ENGINE AVAILABILITY (LONG BLOCK)
    APR 94 2. A/C 0-RING REPLACEMENT
    MAR 94 3. PARTIAL ENGINE (LONG BLOCK) AVAILABILITY
    FEB 94 4. U00194 - 02/28/94
    APR 93 5. PROPER PREPARATION FOR EMISSION INSPECTION TEST
    JAN 93 6. FUEL INJECTOR CLEANER KIT AVAILABLE
    DEC 92 7. AVAILABILITY OF REAR 3 POINT SEAT BELTS
    NOV 92 8. PROOF OF EMISSIONS RECALL CORRECTION LABEL CALIF. VEHICLE
    JUL 92 9. FUEL SYSTEM, MANUAL TRANSMISSION - MANUAL UPDATE
    JUL 92 10. HARD SHIFT TO 2ND GEAR AFTER COLD START
    APR 91 11. REMANUFACTURED EGI CONTROL UNIT EXCHANGE PROGRAM
    FEB 91 12. PREVENT DAMAGING ENGINE REAR OIL SEAL
    DEC 90 13. RECEIVER/DRIER FUSE PLUG ELIMINATION
    DEC 90 14. REMANUFACTURED EGI CONTROL UNITS
    AUG 90 15. EC-AT PROPER CONNECTION
    JUL 90 16. PREVENT DAMAGING REAR OIL SEAL WHILE ASSEMBLING
    JUN 90 17. CRUISE CONTROL WARNING
    JUN 90 18. NOISE FROM REAR SUSPENSION DURING ACCELERATION OR DECELERATION
    JUN 90 19. USE OF TIMING LIGHT ON DISTRIBUTOR-LESS IGNITION SYSTEM
    APR 90 20. SPECIAL TOOLS MODIFICATION
    MAR 90 21. HELM PROGRAM SERVICE COLLATERAL
    FEB 90 22. RECONDITIONED ANTIFREEZE, NOT RECOMMENDED
    DEC 89 23. CPU DAMAGE CAUSED BY WATER LEAKAGE
    DEC 89 24. MISFIRE AND HESITATION OVER 6000 RPM
    DEC 89 25. NOISE FROM THE WATER FLOW INSIDE THE HEATER UNIT
    DEC 89 26. POWER ANTENNA TROUBLESHOOTING
    DEC 89 27. VEHICLE DIFFICULT TO FUEL
    NOV 89 28. REAR 3-POINT SEAT BELT INSTALLATION
    JUL 89 29. REMANUFACTURED EGI CONTROL UNIT PROGRAM
    JUN 89 30. AUTOMATIC TRANSMISSION DRIVEN PLATE PARTS CATALOG REVISION
    JUN 89 31. HARD SHIFT IN LOW TEMPERATURE
    MAY 89 32. AUDIO SYSTEM TROUBLESHOOTING
    MAR 89 33. STATIC ELECTRICITY SHOCK
    FEB 89 34. USE OF REGULAR UNLEADED GASOLINE
    NOV 88 35. IMPROPER OPERATION OF POWER WINDOW REGULATOR (Ball Type)
    NOV 88 36. MAINTENANCE FREE BATTERY CHARGING & TESTING PROCEDURES
    OCT 88 37. COLD ENGINE HARD TO START
    SEP 88 38. USE OF CORPORATE LOGO
    JUN 88 39. FRONT BRAKE CALIPERS, PAD, ETC.
    MAY 88 40. EGI CONTROL UNIT & FUEL INJECTORS
    MAY 88 41. NO. 2 PRE-CONVERTER BRACKET
    APR 88 42. ROUGH IDLE
    APR 88 43. AIR BLEED SOCKETS
    APR 88 44. MAINTENANCE FREE BATTERY
    MAR 88 45. TRANSMISSION BEARINGS
    FEB 88 46. SURGE OR STUMBLE DURING ACCELERATION
    FEB 88 47. ECCENTRIC SHAFT PULLEY BOLT
    JAN 88 48. HEATER & A/C SYSTEM REPAIR
    NOV 87 49. HARD START WITH COLD ENGINE
    NOV 87 50. ENGINE SPEED INCREASES EXCESSIVELY AT COLD STARTING
    NOV 87 51. Hesitation, Bucking, Ignition Misfire, Engine Stall
    NOV 87 52. Poor Performance From Fuel Injector
    NOV 87 53. CLUSTER SWITCH
    OCT 87 54. HARD START AFTER HEAT SOAK
    AUG 87 55. AUTO CRUISE CONTROL O/D CANCEL SYSTEM OF 4-SPEED A/T MODELS
    AUG 87 56. OPERATION OF ETR (ELECTRONICALLY TUNED RADIO) SCAN TUNING BUTTON
    JUL 87 57. FLYWHEEL TURNING TOOL
    JUL 87 58. FUEL TANK FILLER PIPE HOSE
    MAY 87 59. RADIO RECEPTION PROBLEM USING SCAN
    APR 87 60. CUSTOMER ASSISTANCE FOR TIRE PROBLEMS
    APR 87 61. OIL PRESSURE GAUGE ADAPTER
    MAR 87 62. COOLANT LOSS
    MAR 87 63. SPEEDOMETER DRIVEN GEAR SLEEVE
    FEB 87 64. A/C CAUTION LABEL
    JAN 87 65. SHIFT INDICATOR LIGHT (SIL) TROUBLESHOOTING
    JAN 87 66. WATER FLOW NOISE FROM HEATER
    DEC 86 67. Company Name Change for Vendor
    DEC 86 68. RX-7 Heater Amp Control Box (FB01 61 185)
    86 69. MODIFIED DEFLECTOR LINK
    OCT 86 70. AUTOMATIC TRANSMISSION FLUID
    OCT 86 71. Actuator Modification
    OCT 86 72. CPU Damage from Water Leak
    OCT 86 73. KEY ILLUMINATION HARNESS (OUTER DOOR HANDLE)
    SEP 86 74. 1986 & 1987 RX-7 Spark Plug Service Program
    SEP 86 75. FIRST AND SECOND GEAR SYNCHRONIZER RING MODIFICATION
    AUG 86 76. FRONT WHEEL HUB
    AUG 86 77. S.R.T. MANUAL REVISION
    AUG 86 78. WHEEL ALIGNMENT TOE CONTROL HUB
    JUL 86 79. MANUAL TRANSMISSION MODIFICATION OF OVER TOP GEAR & COUNTER GEA
    JUL 86 80. MODIFICATIONS FOR IMPROVED DOOR GLASS OPERATION (POWER & MANUAL
    JUL 86 81. REAR SUSPENSION SUB-FRAME WASHER
    JUN 86 82. CORRECTION TO WORKSHOP MANUAL/FRICTION PLATES
    JUN 86 83. High Mount Stop Lamp
    JUN 86 84. MODIFIED REAR WINDOW
    JUN 86 85. REAR WINDOW DEFROSTER HARNESS
    JUN 86 86. REVISION TO AIR CONDITIONING S.R.T. MANUAL
    MAY 86 87. ALIGNMENT SPECIFICATIONS
    MAY 86 88. COMPACT DISC SYSTEM OPERATION TEMPORARY PAUSE IN DISC PLAY
    MAY 86 89. CORRECTION TO WORKSHOP MANUAL/TRANSMISSION LUBRICANTS
    MAY 86 90. DOOR GLASS ADJUSTER MODIFICATION
    MAY 86 91. NEW KEY BLANKS AVAILABLE FOR PRIMARY KEY
    MAY 86 92. PROPER TORQUE OF A/C COMPRESSOR BLOCK FITTING BOLT
    MAY 86 93. REVISION OF S.R.T. MANUAL
    MAY 86 94. Throttle Sensor Checker
    APR 86 95. Poor Fuel Economy, Performance And Emissions
    APR 86 96. CLUTCH ALIGNMENT PINS
    APR 86 97. CLUTCH DISC
    APR 86 98. INSTALLATION OF 2-WAY (CB) RADIOS
    APR 86 99. INSTALLATION OF AERO PARTS ACCESSORIES (PREPARATION)
    APR 86 100. Modification of ACC Checker
    APR 86 101. REAR SUSPENSION CONTROL LINK
    APR 86 102. REAR SUSPENSION SUB-FRAME NUTS
    MAR 86 103. WORKSHOP MANUAL CORRECTIONS
    MAR 86 104. COMPACT DISC SYSTEM
    MAR 86 105. WORKSHOP MANUAL CORRECTIONS/LABELS
    FEB 86 106. CPU MODIFICATION
    FEB 86 107. Special Tools for the 1986 323, 626 & RX-7
    DEC 85 108. MAT SET PLATE FOR REAR SEAT
    DEC 85 109. POWER ANTENNA MODIFICATION
    DEC 85 110. Pre-Delivery Inspection Sheet Correction
    NOV 85 111. FUSES TO BE INSTALLED AT PDI
    NOV 85 112. Spark Plugs
    OCT 85 113. OPTIONAL NEW AIR DAM SKIRT INSTALLATION
    SEP 85 114. Audio Systems
    AUG 85 115. 1986 BEGINNING VINs
    AUG 85 116. 1986 Pre-Delivery Inspection
    MAR 85 117. P..D.I. AND FIRST FREE INSPECTION

    Year: 1987

    Make: Mazda

    Model: RX7

    Engine: 2RTR-1308cc 80

    JUN 94 1. PARTIAL ENGINE AVAILABILITY (LONG BLOCK)
    APR 94 2. A/C 0-RING REPLACEMENT
    MAR 94 3. PARTIAL ENGINE (LONG BLOCK) AVAILABILITY
    FEB 94 4. U00194 - 02/28/94
    APR 93 5. PROPER PREPARATION FOR EMISSION INSPECTION TEST
    JAN 93 6. FUEL INJECTOR CLEANER KIT AVAILABLE
    DEC 92 7. AVAILABILITY OF REAR 3 POINT SEAT BELTS
    NOV 92 8. PROOF OF EMISSIONS RECALL CORRECTION LABEL CALIF. VEHICLE
    SEP 92 9. HARD SHIFTING AFTER COLD WEATHER - R TYPE TRANSMISSION
    JUL 92 10. FUEL SYSTEM, MANUAL TRANSMISSION - MANUAL UPDATE
    JUL 92 11. HARD SHIFT TO 2ND GEAR AFTER COLD START
    APR 91 12. REMANUFACTURED EGI CONTROL UNIT EXCHANGE PROGRAM
    FEB 91 13. PREVENT DAMAGING ENGINE REAR OIL SEAL
    DEC 90 14. RECEIVER/DRIER FUSE PLUG ELIMINATION
    DEC 90 15. REMANUFACTURED EGI CONTROL UNITS
    AUG 90 16. EC-AT PROPER CONNECTION
    JUL 90 17. PREVENT DAMAGING REAR OIL SEAL WHILE ASSEMBLING
    JUN 90 18. CRUISE CONTROL WARNING
    JUN 90 19. NOISE FROM REAR SUSPENSION DURING ACCELERATION OR DECELERATION
    MAY 90 20. USE OF TIMING LIGHT ON DISTRIBUTOR-LESS IGNITION SYSTEM
    MAR 90 21. SPECIAL TOOLS MODIFICATION
    MAR 90 22. HELM PROGRAM SERVICE COLLATERAL
    JAN 90 23. RECONDITIONED ANTIFREEZE, NOT RECOMMENDED
    DEC 89 24. A/C BUZZING NOISE
    DEC 89 25. MISFIRE AND HESITATION OVER 6000 RPM
    DEC 89 26. NOISE FROM THE WATER FLOW INSIDE THE HEATER UNIT
    DEC 89 27. POOR AIR CONDITIONING COOLING PERFORMANCE
    DEC 89 28. POWER ANTENNA TROUBLESHOOTING
    DEC 89 29. VEHICLE DIFFICULT TO FUEL
    NOV 89 30. REAR 3-POINT SEAT BELT INSTALLATION
    JUL 89 31. PROGRAM
    JUN 89 32. AUTOMATIC TRANSMISSION DRIVEN PLATE PARTS CATALOG REVISION
    JUN 89 33. HARD SHIFT IN LOW TEMPERATURE
    MAY 89 34. AUDIO SYSTEM TROUBLESHOOTING
    MAR 89 35. STATIC ELECTRICITY SHOCK
    FEB 89 36. USE OF REGULAR UNLEADED GASOLINE
    NOV 88 37. IMPROPER OPERATION OF POWER WINDOW REGULATOR (Ball Type)
    NOV 88 38. MAINTENANCE FREE BATTERY CHARGING & TESTING PROCEDURES
    OCT 88 39. COLD ENGINE HARD TO START
    OCT 88 40. TURBOCHARGER FLANGE
    SEP 88 41. USE OF CORPORATE LOGO
    JUN 88 42. FRONT BRAKE CALIPERS, PAD, ETC.
    MAY 88 43. EGI CONTROL UNIT & FUEL INJECTORS
    MAY 88 44. NO. 2 PRE-CONVERTER BRACKET
    APR 88 45. ROUGH IDLE
    APR 88 46. AIR BLEED SOCKETS
    APR 88 47. MAINTENANCE FREE BATTERY
    MAR 88 48. TRANSMISSION BEARINGS
    FEB 88 49. SURGE OR STUMBLE DURING ACCELERATION
    FEB 88 50. ROUGH IDLE OR STALL AFTER COLD START
    FEB 88 51. CLUTCH DISC
    FEB 88 52. ECCENTRIC SHAFT PULLEY BOLT
    JAN 88 53. HEATER & A/C SYSTEM REPAIR
    NOV 87 54. HARD START WITH COLD ENGINE
    NOV 87 55. ENGINE SPEED INCREASES EXCESSIVELY AT COLD STARTING
    NOV 87 56. Hesitation, Bucking, Ignition Misfire, Engine Stall
    NOV 87 57. Poor Performance From Fuel Injector
    NOV 87 58. HARD START AFTER HEAT SOAK
    SEP 87 59. NORMAL CONDITIONS OF FM & AM RADIO RECEPTION
    AUG 87 60. AUTO CRUISE CONTROL O/D CANCEL SYSTEM OF 4-SPEED A/T MODELS
    AUG 87 61. OPERATION OF ETR (ELECTRONICALLY TUNED RADIO) SCAN TUNING BUTTON
    JUL 87 62. BRAKE MASTER CYLINDER
    JUL 87 63. CORRECTION & MODIFICATION OF A/C HOSE CLAMP
    JUL 87 64. CENTERSHAFT GEAR
    JUL 87 65. ENGINE COOLANT
    JUL 87 66. FLYWHEEL TURNING TOOL
    JUL 87 67. FUEL TANK FILLER PIPE HOSE
    JUL 87 68. INSTALLATION OF A/C DISCHARGE HOSE
    JUL 87 69. LOWER ARM & STABILIZER BRACKET
    JUL 87 70. SPECIAL TOOL REPAIR
    JUN 87 71. COIL SPRING COMPRESSOR APPLICATION
    JUN 87 72. COMPRESSOR REFRIGERANT LEAKAGE
    JUN 87 73. MODIFIED CLUTCH DISC
    MAY 87 74. BRAKE PROPORTIONING BYPASS VALVE
    MAY 87 75. RADIO RECEPTION PROBLEM USING SCAN
    MAY 87 76. REAR STABILIZER BRACKETS & PLATES
    MAY 87 77. REVERSE GEAR SYNCHRONIZER RING
    MAY 87 78. S.R.T. MANUAL REVISION - RADIO SYS. & TRANS. REPAIR TIM
    APR 87 79. Hard Starting, Rough Idle Or Poor Acceleration
    APR 87 80. CHANGE OF LOCATION FOR PLACING REBUILT ROTARY ENGINE ORDERS
    APR 87 81. CUSTOMER ASSISTANCE FOR TIRE PROBLEMS
    APR 87 82. OIL PRESSURE GAUGE ADAPTER
    APR 87 83. ORIGINAL EQUIPMENT TIRES
    APR 87 84. S.R.T. MANUAL REVISION - MAINTENANCE & REPAIR TIME
    MAR 87 85. ALIGNMENT SPECIFICATIONS
    MAR 87 86. COOLANT LOSS
    MAR 87 87. CORRECTION TO AIR CONDITIONER INSTALLATION INSTRUCTION
    MAR 87 88. SPEEDOMETER DRIVEN GEAR SLEEVE
    FEB 87 89. A/C CAUTION LABEL
    FEB 87 90. SHIFT INDICATOR LIGHT (SIL) TROUBLESHOOTING
    FEB 87 91. WIRE HARNESS FOR RIGHT-HAND SIDE CLUSTER SWITCH
    JAN 87 92. WATER FLOW NOISE FROM HEATER
    DEC 86 93. Air Control Valve Tester
    DEC 86 94. Power Steering Control Unit
    DEC 86 95. RX-7 Heater Amp Control Box (FB01 61 185)
    NOV 86 96. MODIFIED DEFLECTOR LINK
    NOV 86 97. SYNCHRONIZER RINGS
    NOV 86 98. WORKSHOP MANUAL CORRECTIONS
    OCT 86 99. AUTOMATIC TRANSMISSION FLUID
    OCT 86 100. KEY ILLUMINATION HARNESS (OUTER DOOR HANDLE)
    SEP 86 101. 1986 & 1987 RX-7 Spark Plug Service Program
    SEP 86 102. FIRST AND SECOND GEAR SYNCHRONIZER RING MODIFICATION
    SEP 86 103. OIL SEAL AND COMPANION FLANGE
    AUG 86 104. 1987 BEGINNING VINS
    AUG 86 105. FRONT WHEEL HUB
    AUG 86 106. S.R.T. MANUAL REVISION
    AUG 86 107. WHEEL ALIGNMENT TOE CONTROL HUB
    JUL 86 108. REAR SUSPENSION SUB-FRAME WASHER
    JUN 86 109. CORRECTION TO WORKSHOP MANUAL
    JUN 86 110. High Mount Stop Lamp
    JUN 86 111. REAR WINDOW DEFROSTER HARNESS
    MAY 86 112. Throttle Sensor Checker
    APR 86 113. BEGINNING VIN FOR 1987 RX-7 TURBO

    Year: 1988

    Make: Mazda

    Model: RX7

    Engine: 2RTR-1308cc 80

    JUN 94 1. PARTIAL ENGINE AVAILABILITY (LONG BLOCK)
    APR 94 2. A/C 0-RING REPLACEMENT
    MAR 94 3. PARTIAL ENGINE (LONG BLOCK) AVAILABILITY
    FEB 94 4. U00194 - 02/28/94
    PR 93 5. PROPER PREPARATION FOR EMISSION INSPECTION TEST
    JAN 93 6. FUEL INJECTOR CLEANER KIT AVAILABLE
    DEC 92 7. AVAILABILITY OF REAR 3 POINT SEAT BELTS
    NOV 92 8. PROOF OF EMISSIONS RECALL CORRECTION LABEL CALIF. VEHICLE
    SEP 92 9. HARD SHIFTING AFTER COLD WEATHER - R TYPE TRANSMISSION
    JUL 92 10. FUEL SYSTEM, MANUAL TRANSMISSION - MANUAL UPDATE
    JUL 92 11. HARD SHIFT TO 2ND GEAR AFTER COLD START
    APR 91 12. REMANUFACTURED EGI CONTROL UNIT EXCHANGE PROGRAM
    FEB 91 13. PREVENT DAMAGING ENGINE REAR OIL SEAL
    DEC 90 14. RECEIVER/DRIER FUSE PLUG ELIMINATION
    DEC 90 15. REMANUFACTURED EGI CONTROL UNITS
    AUG 90 16. EC-AT PROPER CONNECTION
    JUL 90 17. PREVENT DAMAGING REAR OIL SEAL WHILE ASSEMBLING
    JUN 90 18. CRUISE CONTROL WARNING
    JUN 90 19. NOISE FROM THE FRONT STRUT
    20. USE OF TIMING LIGHT ON DISTRIBUTOR-LESS IGNITION SYSTEM
    21. SPECIAL TOOLS MODIFICATION
    22. HELM PROGRAM SERVICE COLLATERAL
    23. RECONDITIONED ANTIFREEZE, NOT RECOMMENDED
    DEC 89 24. AUDIO STORAGE TRAY MAY NOT STAY CLOSED
    DEC 89 25. MISFIRE AND HESITATION OVER 6000 RPM
    DEC 89 26. POWER ANTENNA TROUBLESHOOTING
    NOV 89 27. REAR 3-POINT SEAT BELT INSTALLATION
    JUL 89 28. REMANUFACTURED EGI CONTROL UNIT PROGRAM
    JUN 89 29. AUTOMATIC TRANSMISSION DRIVEN PLATE PARTS CATALOG REVISION
    JUN 89 30 IN LOW TEMPERATURE
    MAY 89 31. AUDIO SYSTEM TROUBLESHOOTING
    MAR 89 32. STATIC ELECTRICITY SHOCK
    FEB 89 33. USE OF REGULAR UNLEADED GASOLINE
    DEC 88 34. AUDIO STORAGE TRAY
    NOV 88 35. IMPROPER OPERATION OF POWER WINDOW REGULATOR (Ball Type)
    NOV 88 36. MAINTENANCE FREE BATTERY CHARGING & TESTING PROCEDURES
    OCT 88 37. COLD ENGINE HARD TO START
    OCT 88 38. TURBOCHARGER FLANGE
    SEP 88 39. USE OF CORPORATE LOGO
    JUL 88 40. CURRENT DRAW FROM THE BATTERY
    JUN 88 41. DIAGNOSIS & REPAIR OF A/C REFRIGERANT LEAKS
    JUN 88 42. REFRIGERANT CHARGE SERVICE
    JUN 88 43. ALIGNMENT SPECIFICATIONS
    JUN 88 44. FRONT BRAKE CALIPERS, PAD, ETC.
    MAY 88 45. EGI CONTROL UNIT & FUEL INJECTORS
    MAY 88 46. NO. 2 PRE-CONVERTER BRACKET
    MAY 88 47. AIR CONDITIONER KIT INSTALLATION
    APR 88 48. COMPANION FLANGE & PROPELLER SHAFT
    APR 88 49. ROUGH IDLE
    APR 88 50. AIR BLEED SOCKETS
    APR 88 51. MAINTENANCE FREE BATTERY
    52. ROUGH IDLE OR STALL AFTER COLD START
    FEB 88 53. CLUTCH DISC
    FEB 88 54. HEATER CONTROL (LOGICON)
    JAN 88 55. AUDIO SET IDENTIFICATION NUMBER (ID NO.)
    JAN 88 56. BATTERY (PANASONIC)
    JAN 88 57. HEATER & A/C SYSTEM REPAIR
    NOV 87 58. ENGINE SPEED INCREASES EXCESSIVELY AT COLD STARTING
    NOV 87 59. Poor Performance From Fuel Injector
    NOV 87 60. HARD START AFTER HEAT SOAK
    OCT 87 61. NEW STYLE WIRING DIAGRAM
    SEP 87 62. 1988 BEGINNING VINS
    SEP 87 63. ORIGINAL EQUIPMENT TIRES
    AUG 87 64. CUSTOMER ASSISTANCE FOR TIRE PROBLEMS

    Year: 1989

    Make: Mazda

    Model: RX7

    Engine: 2RTR-1308cc 80

    JUN 94 1. PARTIAL ENGINE AVAILABILITY (LONG BLOCK)
    APR 94 2. A/C 0-RING REPLACEMENT
    MAR 94 3. PARTIAL ENGINE (LONG BLOCK) AVAILABILITY
    FEB 94 4. U00194 - 02/28/94
    APR 93 5. PROPER PREPARATION FOR EMISSION INSPECTION TEST
    JAN 93 6. FUEL INJECTOR CLEANER KIT AVAILABLE
    NOV 92 7. PROOF OF EMISSIONS RECALL CORRECTION LABEL CALIF. VEHICLE
    SEP 92 8. HARD SHIFTING AFTER COLD WEATHER - R TYPE TRANSMISSION
    SEP 92 9. A/C O-RING INSTALLATION PROCEDURE
    JUL 92 10. V BELT TENSION ADJUSTMENT
    JUL 92 11. HARD SHIFT TO 2ND GEAR AFTER COLD START
    OCT 91 12. BRAKE ROTOR AND DRUM INSPECTION
    APR 91 13. REMANUFACTURED EGI CONTROL UNIT EXCHANGE PROGRAM
    MAR 91 14. COOLING, A/T, FUEL SYSTEM - MANUAL CORRECTION
    MAR 91 15. HESITATION ON HARD ACCELERATION BETWEEN 3500-4000 RPM
    FEB 91 16. PREVENT DAMAGING ENGINE REAR OIL SEAL
    DEC 90 17. RECEIVER/DRIER FUSE PLUG ELIMINATION
    DEC 90 18. REMANUFACTURED EGI CONTROL UNITS
    AUG 90 19. EC-AT PROPER CONNECTION
    JUL 90 20. PREVENT DAMAGING REAR OIL SEAL WHILE ASSEMBLING
    JUN 90 21. CRUISE CONTROL WARNING
    JUN 90 22. ELECTRONIC OIL METERING PUMP TERMINALS SWITCHED
    JUN 90 23. NOISE FROM THE FRONT STRUT
    JUN 90 24. SUB-ZERO STARTING ASSIST DEVICE DISCONTINUED, ENGINE MODIFIED
    JUN 90 25. CRUISE CONTROL OPERATION CHANGED
    JUN 90 26. USE OF TIMING LIGHT ON DISTRIBUTOR-LESS IGNITION SYSTEM
    MAY 90 27. On Vehicle Maintenance Manual Corrections
    APR 90 28. SPECIAL TOOLS MODIFICATION
    MAR 90 29. HELM PROGRAM SERVICE COLLATERAL
    FEB 90 30. RECONDITIONED ANTIFREEZE, NOT RECOMMENDED
    DEC 89 31. USING THE EC-AT TESTER
    DEC 89 32. 407289
    NOV 89 33. ELECTRICAL SHORT MAY CAUSE ROUGH IDLE OR NO START
    NOV 89 34. TORQUE SPECIFICATIONS, OIL NOZZLE & OIL METERING TUBE
    SEP 89 35. IDLE SPEED HUNTING OR FLUCTUATION
    JUL 89 36. REMANUFACTURED EGI CONTROL UNIT PROGRAM
    JUN 89 37. HARD SHIFT IN LOW TEMPERATURE
    MAY 89 38. AUDIO SYSTEM TROUBLESHOOTING
    MAR 89 39. HOOD LATCH ASSEMBLY REMOVAL & REINSTALLATION
    MAR 89 40. INCORRECT HORN WIRING HARNESS ROUTING
    MAR 89 41. STATIC ELECTRICITY SHOCK
    FEB 89 42. USE OF REGULAR UNLEADED GASOLINE
    FEB 89 43. PROPER INSTALLATION OF CHANGE ROD BOOT
    NOV 88 44. MAINTENANCE FREE BATTERY CHARGING & TESTING PROCEDURES
    SEP 88 45. USE OF CORPORATE LOGO

    Year: 1990

    Make: Mazda

    Model: RX7

    Engine: 2RTR-1308cc 80

    JUN 94 1. PARTIAL ENGINE AVAILABILITY (LONG BLOCK)
    APR 94 2. A/C 0-RING REPLACEMENT
    MAR 94 3. PARTIAL ENGINE (LONG BLOCK) AVAILABILITY
    FEB 94 4. U00194 - 02/28/94
    APR 93 5. PROPER PREPARATION FOR EMISSION INSPECTION TEST
    APR 93 6. OIL SMELL AROUND THE SHIFTER LEVER
    JAN 93 7. FUEL INJECTOR CLEANER KIT AVAILABLE
    NOV 92 8. PROOF OF EMISSIONS RECALL CORRECTION LABEL CALIF. VEHICLE
    SEP 92 9. HARD SHIFTING AFTER COLD WEATHER - R TYPE TRANSMISSION
    SEP 92 10. A/C O-RING INSTALLATION PROCEDURE
    JUL 92 11. V BELT TENSION ADJUSTMENT
    JUL 92 12. HARD SHIFT TO 2ND GEAR AFTER COLD START
    OCT 91 13. BRAKE ROTOR AND DRUM INSPECTION
    APR 91 14. REMANUFACTURED EGI CONTROL UNIT EXCHANGE PROGRAM
    MAR 91 15. HESITATION ON HARD ACCELERATION BETWEEN 3500-4000 RPM
    FEB 91 16. PREVENT DAMAGING ENGINE REAR OIL SEAL
    DEC 90 17. RECEIVER/DRIER FUSE PLUG ELIMINATION
    DEC 90 18. REMANUFACTURED EGI CONTROL UNITS
    AUG 90 19. EC-AT PROPER CONNECTION
    JUL 90 20. PREVENT DAMAGING REAR OIL SEAL WHILE ASSEMBLING
    JUN 90 21. CRUISE CONTROL WARNING
    JUN 90 22. ELECTRONIC OIL METERING PUMP TERMINALS SWITCHED
    JUN 90 23. SUB-ZERO STARTING ASSIST DEVICE DISCONTINUED, ENGINE MODIFIED
    JUN 90 24. CRUISE CONTROL OPERATION CHANGED
    JUN 90 25. KEY MISTAKENLY LEFT ON ACC
    JUN 90 26. USE OF TIMING LIGHT ON DISTRIBUTOR-LESS IGNITION SYSTEM
    MAY 90 27. On Vehicle Maintenance Manual Corrections
    APR 90 28. SPECIAL TOOLS MODIFICATION
    MAR 90 29. HELM PROGRAM SERVICE COLLATERAL
    MAR 90 30. A/C SYSTEMS GAS-CHARGE AMOUNTS
    FEB 90 31. RECONDITIONED ANTIFREEZE, NOT RECOMMENDED
    DEC 89 32. USING THE EC-AT TESTER
    DEC 89 33. 407289
    NOV 89 34. ELECTRICAL SHORT MAY CAUSE ROUGH IDLE OR NO START
    NOV 89 35. TORQUE SPECIFICATIONS, OIL NOZZLE & OIL METERING TUBE
    OCT 89 36. 1990 BEGINNING VINS
    SEP 89 37. IDLE SPEED HUNTING OR FLUCTUATION
    MAY 89 38. AUDIO SYSTEM TROUBLESHOOTING

    Year: 1991

    Make: Mazda

    Model: RX7

    Engine: 2RTR-1308cc 80

    JUN 94 1. PARTIAL ENGINE AVAILABILITY (LONG BLOCK)
    2. A/C 0-RING REPLACEMENT
    3. PARTIAL ENGINE (LONG BLOCK) AVAILABILITY
    FEB 94 4. U00194 - 02/28/94
    APR 93 5. PROPER PREPARATION FOR EMISSION INSPECTION TEST
    APR 93 6. OIL SMELL AROUND THE SHIFTER LEVER
    JAN 93 7. FUEL INJECTOR CLEANER KIT AVAILABLE
    DEC 92 8. PROOF OF EMISSIONS RECALL CORRECTION LABEL CALIF. VEHICLE
    SEP 92 9. HARD SHIFTING AFTER COLD WEATHER - R TYPE TRANSMISSION
    SEP 92 10. A/C O-RING INSTALLATION PROCEDURE
    JUL 92 11. MODIFIED A/C COMPRESSOR
    JUL 92 12. V BELT TENSION ADJUSTMENT
    JUL 92 13. HARD SHIFT TO 2ND GEAR AFTER COLD START
    OCT 91 14. BRAKE ROTOR AND DRUM INSPECTION
    MAY 91 15. TECHNICAL ASSISTANCE 800 PHONE LINES
    APR 91 16. REMANUFACTURED EGI CONTROL UNIT EXCHANGE PROGRAM
    MAR 91 17. HOOD LATCH LUBRICATION MAINTENANCE
    MAR 91 18. HESITATION ON HARD ACCELERATION BETWEEN 3500-4000 RPM
    FEB 91 19. TIRE PRESSURE CHECK DURING PDI
    DEC 90 20. RECEIVER/DRIER FUSE PLUG ELIMINATION
    DEC 90 21. REMANUFACTURED EGI CONTROL UNITS
    OCT 90 22. NOISE & VIBRATION REPAIR SUMMARY
    OCT 90 23. 1991 VIN NUMBERS
    24. SPECIAL TOOLS MODIFICATION

    Year: 1992

    Make: Mazda

    Model: RX7

    Engine: 2RTR-1308cc 80

    JUN 94 1. PARTIAL ENGINE AVAILABILITY (LONG BLOCK)
    MAR 94 2. A/C 0-RING REPLACEMENT
    MAR 94 3. PARTIAL ENGINE (LONG BLOCK) AVAILABILITY
    FEB 94 4. U00194 - 02/28/94
    APR 93 5. PROPER PREPARATION FOR EMISSION INSPECTION TEST
    JAN 93 6. FUEL INJECTOR CLEANER KIT AVAILABLE
    NOV 92 7. PROOF OF EMISSIONS RECALL CORRECTION LABEL CALIF. VEHICLE
    APR 92 8. TRANSIT COATING REMOVAL
    JAN 92 9. PRE-DELIVERY ADMINISTRATIVE MATERIAL
    DEC 91 10. PERFECT DELIVERY PRE-DELIVERY INSPECTION ITEMS
    BRAKE ROTOR AND DRUM INSPECTION

    Thanks to:

    Tuck for being the main contributor and publisher of this comprehensive list. Keep up the good work!

    Jeff Nappi and Reto for putting together and running the RX-7net.

    Don St.John, for the CPU cold solder fix.

    Dana Sullivan, for the 3800 rpm hesitation fix and the TPS test light construction instructions.

    Trey Cobb, for the Turbo II Performance FAQ.

    Mike Mario, for the Logicon Fix and TSB title list.

    Everyone else.