Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Engine

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REMOVAL & INSTALLATION



Be sure that the engine has completely cooled before attempting to remove it.

1979-85 Carbureted RX-7
  1. Disconnect the negative battery cable. Scribe matchmarks on the hood and hinges, then remove the hood.
  2.  
  3. Working from underneath the vehicle, remove the gravel shield, then drain the cooling system and engine oil into separate containers.
  4.  
  5. Disconnect the high tension wires from the center towers of the ignition coils.
  6.  

A good rule of thumb when disconnecting the engine wiring and vacuum hoses, is to first mark each pair of wires/hoses with a numbered piece of masking tape. Use the same number on both sides of a connection, but be sure to number each set of connections differently. When reconnecting the wires/hoses, simply match the pieces of tape.

  1. Disconnect the distributor wiring, the oil level sensor lead, the water temperature lead and, on all except California vehicles, the coupler from the oil thermosensor.
  2.  
  3. On all California vehicles and on vehicles equipped with an automatic transmission, disconnect the vacuum sensing tube from the vacuum switch. Disconnect the evaporative hose.
  4.  
  5. Disconnect the hoses from the oil cooler, located beneath the radiator. Disconnect the radiator coolant level sensor lead from the top of the radiator, and disconnect the coolant reservoir hose.
  6.  
  7. Unfasten the bolts, then remove the drive pulley from the cooling fan and drive unit. Remove the air cleaner assembly.
  8.  

On vehicles equipped with air conditioning, it will be necessary to remove the compressor and the condenser from their mounts. Do not unfasten the refrigerant lines. Tie the units off to a convenient place on the body or engine compartment.

  1. On all vehicles, except California and Canada, detach the connectors from the No. 2 water temperature sensor, located on the radiator next to the radiator cap.
  2.  
  3. Disconnect the lower and upper radiator hoses. If equipped, disconnect the automatic transmission fluid lines at the radiator.
  4.  
  5. Remove the cooling fan/drive unit, along with the radiator and fan shroud assembly.
  6.  
  7. Disconnect the vacuum hose for the brake booster. Disconnect the heat exchanger pipe from the rear of the intake manifold.
  8.  
  9. Disconnect the coupler from the power valve solenoid, on all except Canadian vehicles equipped with a manual transmission.
  10.  
  11. Disconnect the coasting enrichment connector on vehicles equipped with a manual transmission. Disconnect the leads from the choke heater and the anti-afterburn solenoid. Disconnect the idle switch coupler on manual transmission equipped vehicles. Disconnect the throttle sensor, the MAB solenoid valve, the idle richer solenoid, and the port air solenoid valve.
  12.  
  13. On all vehicles, except California and Canada, disconnect the lead from the choke return solenoid valve.
  14.  
  15. If equipped, remove the rear cover from the exhaust manifold.
  16.  
  17. Disconnect the accelerator, choke and hot start assist cables.
  18.  
  19. Disconnect the fuel lines from the carburetor and plug the fuel intake line to prevent leakage. Disconnect the cruise control cable, if equipped.
  20.  
  21. Disengage the wiring connector and the "B" terminal from the alternator. On all vehicles, except California, disconnect the sub-zero start assist hose.
  22.  
  23. Disconnect the wiring from the No. 1 water temperature vacuum switch, the 3-way valve, the engine strap and the air vent solenoid. Disconnect the heater hoses from the engine.
  24.  
  25. From underneath the vehicle, disconnect and remove the starter. Remove the engine to transmission bolts.
  26.  
  27. On automatic transmission vehicles, remove the converter housing lower cover, matchmark the drive plate in relation to the torque converter, then remove the torque converter-to-drive plate bolts.
  28.  
  29. Disconnect all interfering exhaust system components.
  30.  
  31. Support the front of the transmission with a floor jack, then remove the left and right side engine mount bolts.
  32.  
  33. Attach a suitable sling to the engine hanger brackets, then raise the engine with a hoist slightly.
  34.  
  35. Pull the engine forward until it clears the clutch shaft or torque converter, then lift it out of the vehicle.
  36.  
  37. Mount the engine on a suitable engine stand. Remove the valve and piping assemblies from the engine.
  38.  

A special three-part workstand, designed for the rotary engine, is available from Mazda.

To install:
  1. Install the engine valve and piping assemblies. Reconnect the sling to the lifting brackets and connect a suitable lifting hoist to the sling.
  2.  
  3. Lower and guide the engine into the vehicle until it engages the clutch shaft or torque converter. Once the engine is in place, tension the hoist slightly to hold it there. Install the right and left engine mount bolts. Remove the jack from underneath the transmission.
  4.  
  5. Connect all exhaust components that were disconnected for engine removal clearance.
  6.  
  7. On automatic transmission equipped vehicles, attach the drive plate to the torque converter using the previously made alignment marks. Install the retaining bolts, after rotating the engine as necessary. Install the torque converter housing lower cover.
  8.  
  9. Install and tighten the lower engine-to-transmission bolts. Install the starter.
  10.  
  11. Connect the heater hose to the left side of the engine. Connect the electrical wiring to the air solenoid and water temperature switch.
  12.  
  13. Connect the alternator wiring. Connect the sub-zero start assist hose, if applicable.
  14.  
  15. Unplug and connect the fuel lines to the carburetor.
  16.  
  17. Connect the hot start assist, choke and accelerator cables. If equipped, install the exhaust manifold rear cover.
  18.  
  19. Install the two upper engine-to-transmission bolts.
  20.  
  21. On 1980 and later models, except California and Canada, connect the electrical lead to the choke return solenoid valve.
  22.  
  23. On manual transmission equipped vehicles, connect the idle switch coupler and coasting enrichment connector. Connect the leads to the choke heater and the anti-afterburn solenoid.
  24.  
  25. On all 1980 models, 1979 models equipped with automatic transmission, and California manual transmission equipped models, connect the power solenoid valve coupler.
  26.  
  27. Connect the heat exchanger pipe to the rear of the intake manifold. Connect the brake booster vacuum hose.
  28.  
  29. Install the radiator and fan shroud assembly.
  30.  
  31. On automatic transmission equipped vehicles, connect the transmission fluid cooler lines to the radiator.
  32.  
  33. On all 1980 and later models (except California and Canada), fasten the connectors for the No. 2 water temperature sensor, located next to the radiator cap. If equipped, install the air conditioning compressor and condenser onto their mounts.
  34.  
  35. Install the air cleaner assembly and associated brackets. Attach the cooling fan and drive unit to the drive pulley, then install the retaining bolts.
  36.  
  37. Attach the coolant reservoir hose, then connect the radiator coolant temperature sensor lead at the top portion of the radiator. Working from the bottom of the radiator, connect the oil cooler hoses.
  38.  
  39. Connect the evaporative hose. On all California models, and on all 1980 and later models equipped with an automatic transmission, connect the vacuum sensing tube to the vacuum switch.
  40.  
  41. On all models with the exception of California, connect the oil thermosensor coupler. Connect the water temperature and oxygen sensor leads. Connect the distributor wires.
  42.  
  43. Connect the wires to the center towers of the ignition coils. Connect the negative battery cable.
  44.  
  45. Fill the crankcase and the cooling system to their proper levels (see the Capacities chart in General Information & Maintenance ). Install the gravel shield from underneath the car.
  46.  
  47. Position and install the hood onto its hinges using the alignment marks made previously.
  48.  
  49. Adjust all cables, drive belts and linkages. Perform a complete tune-up.
  50.  

1984-89 Fuel Injected RX-7
NON-TURBO

See Figure 1

  1. Properly relieve the fuel system pressure, as described in Fuel System . Disconnect the negative battery cable.
  2.  
  3. Scribe matchmarks on the hood and hinges, then remove the hood.
  4.  
  5. Remove the engine under cover. Drain the coolant and engine oil into separate containers.
  6.  


WARNING
Be sure to consult the laws in your area before servicing the air conditioning system. In most areas, it is illegal to service a refrigerant system without a certified recovery/recycling station. R-12 refrigerant is a chlorofluorocarbon which, when released into the atmosphere, can contribute to depletion of the ozone layer in the upper atmosphere.

  1. As required, properly discharge and recover refrigerant from the air conditioning system, using a proper recycling/recovery station.
  2.  

A good rule of thumb when disconnecting the engine wiring and vacuum hoses, is to first mark each pair of wires/hoses with a numbered piece of masking tape. Use the same number on both sides of a connection, but be sure to number each set of connections differently. When reconnecting the wires/hoses, simply match the pieces of tape.

  1. Disconnect the spark plug wires at the plugs. If so equipped, remove the distributor cap and spark plug wires, along with the rotor. (On 1986-89 models, disconnect the crank angle sensor.) Disconnect the oil pressure gauge and oil temperature gauge wiring harnesses. Disconnect the accelerator cable, fuel lines and evaporator lines. Plug the lines to prevent leakage and contamination.
  2.  
  3. From the left side of the engine compartment, disconnect the air conditioner compressor drive belt and remove the compressor. Remove the power steering pump and mounting brackets. Disconnect the rear oil hose (or oil cooler pipe) and drain the engine oil into a container. Remove the starter cable harness bracket. Disconnect the heater hoses and water temperature gauge unit wiring.
  4.  
  5. From the right side of the engine compartment, remove or disconnect the air pump hose, the air funnel, air flow meter connector and the air cleaner assembly. Disconnect the radiator hoses and heater hose from the radiator.
  6.  
  7. Disconnect the fan wiring harness, then remove the cooling fan and cover (shroud). Disconnect the coolant level sensor, then remove the radiator. Disconnect the oil cooler hoses.
  8.  
  9. Disconnect the cruise control cable and the oil pump metering rod connector. Disconnect the water hoses, brake booster hose and air pump hoses.
  10.  
  11. Detach the intake air temperature sensor connector, the air supply valve connector and the throttle sensor connector. Remove the mounting nut and disconnect the terminal cover wire at the dynamic chamber.
  12.  
  13. If the engine will be disassembled, disconnect the eight vacuum sensor tubes from the dynamic chamber, then unfasten and remove the dynamic chamber from the engine.
  14.  
  15. Unfasten the following wiring connectors: oxygen sensor, fuel injectors, water temperature sensor, vacuum control solenoid valve, pressure regulator control solenoid, vent solenoid, vacuum valve solenoid, engine ground and alternator wiring harness.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Checking cooling fan clearance on fuel injected non-turbo RX-7

  1. Raise and safely support the vehicle. Remove the exhaust pipe front cover and catalytic converter cover. Disconnect the No. 1 Pre-monolith converter from the exhaust manifold. Disconnect the starter motor wiring harness, then remove the starter motor.
  2.  
  3. Remove the transmission-to-engine attaching bolts and the engine mount nuts.
  4.  
  5. Lower the vehicle. Attach a suitable lifting sling to the engine's lifting brackets and to a hoist. Carefully remove the engine after pulling it forward slightly to disengage the transmission.
  6.  
  7. Mount the engine on a stand or suitable holding fixture and remove the sling from the lifting brackets.
  8.  

A special three-part workstand, designed for the rotary engine, is available from Mazda.

To install:
  1. Reconnect the sling to the lifting brackets and connect a hoist to the sling.
  2.  
  3. Lower and guide the engine into the vehicle until it engages the clutch or torque converter input shaft. Once the engine is in place, tension the hoist slightly to hold it there. Install the right and left engine mount bolts, along with the transmission-to-engine bolts.
  4.  
  5. Install the starter motor and connect its wiring harness. Connect the No. 1 pre-monolith converter to the exhaust manifold. Install the catalytic converter cover and exhaust pipe front cover.
  6.  
  7. Connect the alternator wiring harness, engine ground, vacuum valve solenoid, vent solenoid, pressure regulator control solenoid and vacuum control solenoid. Attach the water temperature sensor, fuel injector connectors and oxygen sensor wiring.
  8.  
  9. If applicable, install the dynamic chamber and connect the eight vacuum sensor tubes.
  10.  
  11. Connect the terminal cover wire with the attaching nut. Attach the throttle sensor, air supply valve and intake air temperature sensor wiring connectors.
  12.  
  13. Connect the air pump, brake booster and water hoses. Connect the oil pump metering rod connector and the cruise control cable.
  14.  
  15. Connect the oil cooler hoses. Install the radiator and connect the coolant level sensor.
  16.  
  17. Install the cooling fan and cover, then connect the fan wiring harness. Adjust the cover so that there is 0.63-0.94 in. (16-24mm) clearance from the tip of the fan blade to the edge of the cover.
  18.  
  19. Install the radiator and heater hoses. From the right side of the engine, connect/install the air cleaner assembly and brackets, air flow meter connector, air funnel and air pump hose.
  20.  
  21. Connect the heater hoses and temperature gauge unit wiring at the engine. Install the starter wiring harness bracket. Connect the rear oil hose. Install the power steering pump mounting bracket and the power steering pump. Install the air conditioning compressor with the drive belt.
  22.  
  23. Connect the evaporator and fuel lines, then connect the accelerator cable. Connect the wiring harnesses to the oil temperature and pressure gauges.
  24.  
  25. From the left side of the engine, install the rotor and distributor cap (or connect the crank angle sensor). Connect the spark plug wires.
  26.  


WARNING
Be sure to consult the laws in your area before charging the air conditioning system. In most areas it is illegal to service a system without a certified recovery/recycling station. R-12 refrigerant is a chlorofluorocarbon which, when released into the atmosphere, can contribute to depletion of the ozone layer in the upper atmosphere.

  1. Charge the air conditioning system, using the proper equipment.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. Fill the crankcase and the cooling system to their proper levels (see the Capacities chart in General Information & Maintenance ).
  6.  
  7. Position and install the hood onto its hinges, using the alignment marks made previously.
  8.  
  9. Adjust all cables and linkages. Perform a complete tune-up.
  10.  

TURBO
  1. Properly relieve the fuel system pressure, as described in Fuel System . Disconnect the negative battery cable.
  2.  
  3. Drain the engine oil and coolant into separate containers.
  4.  
  5. Starting from the front and right side of the engine, remove the following components:
    1. Air intake pipe and air cleaner assembly.
    2.  
    3. Battery and battery box.
    4.  
    5. Cooling fan and upper and lower radiator hoses.
    6.  
    7. Heater return hose, coolant level sensor connector and radiator switch connector. Remove the automatic transmission fluid hose (1987-89 vehicles only).
    8.  
    9. Radiator, cowling and intercooler.
    10.  
    11. Accelerator cable and, if equipped, cruise control cable. Brake vacuum hose, pressure sensor vacuum hose, relief silencer hose and spilt air pipe.
    12.  
    13. Oxygen sensor connector, insulator covers, front converter upper nut and engine harness connector.
    14.  

  6.  
  7. Working from the left side of the engine, remove/disconnect the following components:
    1. Power steering pump and drive belt. Leave the hoses connected to the power steering pump and secure it out of the way.
    2.  
    3. Air conditioning compressor and drive belt. Leave the hoses connected to the compressor and secure it out of the way.
    4.  
    5. Spark plug wires, crank angle sensor connector and alternator connector.
    6.  
    7. Canister hose. Remove and plug the fuel hose.
    8.  
    9. Oil pressure connector, heater hose, clutch release cylinder, engine ground and oil cooler pipe and bracket.
    10.  

  8.  
  9. Raise and safely support the vehicle. Remove the under cover and catalytic converter insulator. Disconnect the split air pipe, exhaust pipe bracket and catalytic converter. Remove the exhaust pipe and front converter, starter, transmission attaching bolts and engine mounting nuts.
  10.  
  11. Lower the vehicle, then attach a suitable lifting sling and hoist to the engine lifting brackets and a hoist. Carefully remove the engine after pulling it forward slightly to disengage the transmission.
  12.  
  13. Mount the engine on a stand or suitable holding fixture. Disconnect the sling from the lifting brackets.
  14.  

A special three-part workstand, designed for the rotary engine, is available from Mazda.

To install:
  1. Reconnect the sling to the lifting brackets, then connect a hoist to the sling and carefully raise the engine.
  2.  
  3. Lower and guide the engine into the vehicle until it engages the clutch or torque converter input shaft. Once the engine is in place, tension the hoist slightly to hold it there. Install the right and left engine mount bolts, along with the transmission-to-engine bolts.
  4.  
  5. Install the catalytic converter, exhaust pipe bracket, split air pipe, catalytic converter insulator and the under cover. Lower the vehicle.
  6.  
  7. Working from the left side of the vehicle, install/connect the following components:
    1. Oil cooler pipe and bracket, engine ground, clutch release cylinder, heater hose and the oil pressure switch connector
    2.  
    3. Fuel and canister hoses.
    4.  
    5. Alternator and crank angle sensor connectors. Connect the spark plug wires.
    6.  
    7. Position the air conditioning compressor onto its mounting, slip the drive belt over the pulley and adjust it. Install the power steering pump in the same manner.
    8.  

  8.  
  9. Working from the right and the front sides of the engine, install/connect the following components:
    1. Engine harness connector, front converter upper nut, insulator covers and oxygen sensor connector.
    2.  
    3. Split air pipe, relief silencer hose, pressure sensor vacuum hose, brake vacuum hose, cruise control and accelerator cables.
    4.  
    5. Intercooler, radiator and radiator cowling.
    6.  
    7. Battery box and battery.
    8.  
    9. Air cleaner assembly and air intake pipe.
    10.  

  10.  
  11. Connect the negative battery cable.
  12.  
  13. Fill the crankcase and the cooling system to their proper levels (see the Capacities chart in General Information & Maintenance ).
  14.  
  15. Position and install the hood onto its hinges, using the alignment marks made previously.
  16.  
  17. Adjust all cables and linkages. Perform a complete tune-up.
  18.  

 
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