Service Tips For Performing RX-7 Fuel Line Recall (CAT. AD, NO. 002/96)

MAZDA TIPS (Jan. 1994 ed.)

When performing the Fuel Line Recall on RX-7 (Recall #60504), the following precautions and tips could save you a lot of extra time, and eliminate unnecessary expenses.

• Use extreme caution when removing the Fuel Pressure Regulator vacuum line. The plastic solenoid pipe can be easily broken when removing the hose if caution is not exercised.
• Secondary Fuel Rail Hose Replacement: The fuel injector rails are very fragile and can be easily broken. Remove the fuel distributor assemblies before you remove the Fuel Connector bolt. Do not mount the fuel distributor in a vice. Hold the distributor in your hand and remove the Fuel Connector bolt with an air impact wrench. When installing the new fuel hose, hold the fuel distributor by hand and torque. The fuel connector bolt torque should be adjusted to 240-360 kgs/cm (208-312 in-lbs)
• Fuel Hose Clips: The double clips used on the primary fuel distributor inlet hose are narrower than the other clips. They also have a red holder. The single clips for use on the secondary distributor outlet hose is wider and has a pink holder.
• Fuel System Pressure Test: It is essential that this test be properly completed. The fuel line clips may appear to be properly seated, when in fact they are slightly mispositioned. Only when this pressure test is performed for the full five minutes can you be certain that all joints are well sealed.
• When performing fuel system leak test, it is important to connect the battery negative cable and then install jumper wire from the ground to the fuel pump terminals in the diagnostic connector before tuning the ignition switch on. When the test is completed, turn the ignition switch off, remove the jumper wire, and then disconnect the battery negative cable. Failure to follow this order could result in damage to electrical components, such as the PCM.
• Be sure to use the proper 1Omm nuts to install the coil assembly. The proper nuts have grooves on the underside to ensure a complete ground.
• Be sure that the 0-ring gasket is properly seated on the base of the oil filler. The gasket may come off during removal without being noticed.
• When installing the Catch Tank during reassembly, be sure to route the vacuum hose from the purge control and to the catch tank on the outside of the oil filler. Otherwise, the vacuum hose could interfere in proper operation of the throttle linkage.
• The Fan Control System fastener A is a gray plastic-phillips screw in fastener. Remove and discard the fastener. The bolt at the top of the ECU should be loosened to allow the ECU to be slid down and away from the kick panel. It is not necessary to remove the wiring connectors from the ECU to perform this procedure. Just move the ECU over toward the center of the passenger area floor.

Fig 1: Driveability Troubleshooting Tips, Poor Power/Idle, Hesitates

DESCRIPTION

To improve idle smoothness and engine reliability, the cooling fan control system controls the electrical fan speed by ECM. This system consists of the cooling fan, cooling fan relays, cooling fan control module, ECM, and input devices. See Fig 5 and Fig 6 .

Fig 5: Cooling Fan Control System Components

Fig 6: Cooling Fan Control System Operation

SYSTEM INSPECTION

1. Verify that the engine coolant temperature is below 80°C (176° F)
2. Turn the ignition switch to ON for 15 seconds or longer.
3. Turn the ignition switch to OFF.
4. Ground the check connector by using a jumper wire.
5. (Up to VIN JM1 FD331' PO 210660) Turn the ignition switch to ON and verify that the cooling fan operates. Wait for approximately 150 seconds. (From VIN JM1 FD331'PO 210661) Turn the ignition switch to ON and verify that the cooling fan operates approximately 100-150 seconds after the ignition switch is turned to ON.
6. If the cooling fan will not operate, inspect the following.
   • Battery positive voltage
   • Fan control signal
   • Engine coolant temperature signal
   • Ground
7. Turn the ignition switch to OFF.
8. Verify that the cooling fan keeps operating after the ignition switch is turned to OFF.
9. If not, replace the cooling fan control module. See Fig 7 .
10. Wait for approximately 20 seconds.
11. Disconnect cooling fan relay connector A. Verify that the cooling fan operates at low speed. See Fig 8 .
    Fig 7: Cooling Fan Control Module

    
    Fig 8: Cooling Fan Relay Connector

    
12. If not, inspect the cooling fan relay.
13. Connect cooling fan relay connector A. Verify that the cooling fan operates at the speed before connector A is disconnected.
14. Disconnect the jumper wire from the check connector. Verify that the cooling fan operates at low speed.
15. Turn the ignition switch to ON.
16. Verify that the cooling fan stops 8-12 seconds after the ignition switch is turned to ON.
17. If not as specified, replace the cooling fan control module

REMOVAL/INSTALLATION

1. Remove the ECM.
2. Disconnect the cooling fan control module connector.
3. Loosen nut A as shown. See Fig 9 .
4. Remove the cooling fan control module.
5. Install in the reverse order of removal. Tighten Nut A Torque to 7.9-10.7 N-m (80-110 kgs-cm, 70-95 in-lbs).

Fig 9: Cooling Fan Control Module

INSPECTION

1. Disconnect the cooling fan relay.
2. Apply battery positive voltage and ground to terminals A and B of the cooling fan relay. See Fig 13 .
3. Check continuity of the relay.
   TERMINAL CONTINUITY
   
   

   Operation (1) B+ applied	Specification Continuity
   B+ not applied	No continuity B Type - Terminals C-D
   (1) - A Type - Terminals D-E;

   NOTE: B+ - Battery positive voltage
4. If not as specified, replace the cooling fan relay. For additional wiring schematic information see Fig 14 and Fig 15

Fig 13: Terminals A and B

Fig 14: Wiring Diagram Engine & Fuel Control System 1993 RX-7

Fig 15: Wiring Diagram Coolant Fan System 1993 RX-7