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89 rx7 motor change
02-23-2007, 09:36 PM
Post: #1
89 rx7 motor change
hi guys. i have a 89 rx7 that has a blown motor. i already got another motor thats good, ready to put in, now all i need is step by step instructions on how to take out old motor and install new one. i hope someone can help. thanks. allen
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02-24-2007, 09:12 PM
Post: #2
RE: 89 rx7 motor change
Release fuel system pressure as follows:
Lift up rear floor mat and remove fuel pump cover.
Start engine, then disconnect fuel pump connector.
Run engine until it stalls, then turn off ignition switch and reconnect fuel pump connector.
Disconnect battery ground cable, then scribe hood hinge locations and remove hood.
Drain engine oil and coolant, then remove air intake pipe.
Remove relief silencer hose, then the air cleaner assembly.
Remove cooling fan and radiator hoses, then the heater return hose.
Disconnect coolant level sensor and radiator switch electrical connector.
Remove ATF hose, if equipped, then the radiator and cowling.
Disconnect accelerator cable, then the cruise control cable and vacuum hose, if equipped.
Disconnect brake vacuum hose, BAC air hose and boost sensor vacuum hose.
Disconnect engine harness electrical connectors.
Disconnect spark plug wires, then the crank angle sensor, alternator and oil pressure gauge electrical connectors.
Disconnect engine ground, then the canister hose and heater hose.
Disconnect and plug fuel inlet and return hoses.
Disconnect oil cooler pipe and bracket and A/T pipe bracket, if equipped.
Remove power steering pump and A/C compressor with hoses still connected, then secure pump and compressor to one side, as required.
Remove compressor and pump drive belts, then the dust cover.
Raise and support vehicle, then remove engine under cover and exhaust pipe under cover.
Remove catalytic converter insulator, then the secondary air pipe and hose.
Remove exhaust pipe bracket and exhaust pipe.
Remove starter attaching bolts, then the starter.
On models equipped with automatic transmission, remove torque converter attaching bolts.
On all models, support engine assembly using a suitable jack, then remove transmission to engine attaching bolts.
Remove engine mount, then lower engine from vehicle.
Reverse procedure to install.

Sorry this is all I could find at the time. I will continue looking for more info. and pictures.

Cary Joe York
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02-27-2007, 03:49 AM
Post: #3
RE: 89 rx7 motor change
go to autozone.com and look under their repair manuals and they will give you the information that you are looking for
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02-27-2007, 06:13 PM
Post: #4
RE: 89 rx7 motor change
Here is what I found on the Autozone site. It is text only. No pictures. It may have a little more than my original posting.


1984-89 Fuel Injected RX-7

NON-TURBO

See Figure 1

Properly relieve the fuel system pressure, as described in Fuel System . Disconnect the negative battery cable.

Scribe matchmarks on the hood and hinges, then remove the hood.

Remove the engine under cover. Drain the coolant and engine oil into separate containers.


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.



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

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.

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.

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.

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.

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.

Disconnect the cruise control cable and the oil pump metering rod connector. Disconnect the water hoses, brake booster hose and air pump hoses.

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.

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.

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.


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



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.

Remove the transmission-to-engine attaching bolts and the engine mount nuts.

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.

Mount the engine on a stand or suitable holding fixture and remove the sling from the lifting brackets.

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

To install:

Reconnect the sling to the lifting brackets and connect a hoist to the sling.

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.

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.

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.

If applicable, install the dynamic chamber and connect the eight vacuum sensor tubes.

Connect the terminal cover wire with the attaching nut. Attach the throttle sensor, air supply valve and intake air temperature sensor wiring connectors.

Connect the air pump, brake booster and water hoses. Connect the oil pump metering rod connector and the cruise control cable.

Connect the oil cooler hoses. Install the radiator and connect the coolant level sensor.

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.

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.

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.

Connect the evaporator and fuel lines, then connect the accelerator cable. Connect the wiring harnesses to the oil temperature and pressure gauges.

From the left side of the engine, install the rotor and distributor cap (or connect the crank angle sensor). Connect the spark plug wires.


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.



Charge the air conditioning system, using the proper equipment.

Connect the negative battery cable.

Fill the crankcase and the cooling system to their proper levels (see the Capacities chart in General Information & Maintenance ).

Position and install the hood onto its hinges, using the alignment marks made previously.

Adjust all cables and linkages. Perform a complete tune-up.

TURBO

Properly relieve the fuel system pressure, as described in Fuel System . Disconnect the negative battery cable.

Drain the engine oil and coolant into separate containers.

Starting from the front and right side of the engine, remove the following components:

Air intake pipe and air cleaner assembly.

Battery and battery box.

Cooling fan and upper and lower radiator hoses.

Heater return hose, coolant level sensor connector and radiator switch connector. Remove the automatic transmission fluid hose (1987-89 vehicles only).

Radiator, cowling and intercooler.

Accelerator cable and, if equipped, cruise control cable. Brake vacuum hose, pressure sensor vacuum hose, relief silencer hose and spilt air pipe.

Oxygen sensor connector, insulator covers, front converter upper nut and engine harness connector.

Working from the left side of the engine, remove/disconnect the following components:

Power steering pump and drive belt. Leave the hoses connected to the power steering pump and secure it out of the way.

Air conditioning compressor and drive belt. Leave the hoses connected to the compressor and secure it out of the way.

Spark plug wires, crank angle sensor connector and alternator connector.

Canister hose. Remove and plug the fuel hose.

Oil pressure connector, heater hose, clutch release cylinder, engine ground and oil cooler pipe and bracket.

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.

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.

Mount the engine on a stand or suitable holding fixture. Disconnect the sling from the lifting brackets.

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

To install:

Reconnect the sling to the lifting brackets, then connect a hoist to the sling and carefully raise the engine.

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.

Install the catalytic converter, exhaust pipe bracket, split air pipe, catalytic converter insulator and the under cover. Lower the vehicle.

Working from the left side of the vehicle, install/connect the following components:

Oil cooler pipe and bracket, engine ground, clutch release cylinder, heater hose and the oil pressure switch connector

Fuel and canister hoses.

Alternator and crank angle sensor connectors. Connect the spark plug wires.

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.

Working from the right and the front sides of the engine, install/connect the following components:

Engine harness connector, front converter upper nut, insulator covers and oxygen sensor connector.

Split air pipe, relief silencer hose, pressure sensor vacuum hose, brake vacuum hose, cruise control and accelerator cables.

Intercooler, radiator and radiator cowling.

Battery box and battery.

Air cleaner assembly and air intake pipe.

Connect the negative battery cable.

Fill the crankcase and the cooling system to their proper levels (see the Capacities chart in General Information & Maintenance ).

Position and install the hood onto its hinges, using the alignment marks made previously.

Adjust all cables and linkages. Perform a complete tune-up.

Cary Joe York
Support
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