Mazda RX7. Manual - part 24

1.1L ROTARY

Article Text (p. 10)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 04:57PM

Rotor Bearing Replacement
1) Place rotor bearing on support so internal gear is facing
downward. Using rotor bearing replacer (49 0813 240), without adapter
ring, press bearing out of rotor.
2) Place rotor on support with internal gear facing upward.
Place a new rotor bearing so slot in rotor bore is in line with
bearing lug. Press new bearing (using tool with adapter) until bearing
is flush with rotor boss. See Fig. 13.

Fig. 13: Pressing Rotor Bearing from Rotor
Slot in rotor bore must be in line with bearing lug.

Apex Seal
1) Clean all carbon from apex seal and spring with a cleaning
solution (not emery paper). Measure height of apex seal with a
micrometer. See Fig. 14. Replace seal if height is less than .275" (7.
0 mm).

Fig. 14: Measuring Apex Seal Height
Clean thoroughly before measuring.

2) Check for warpage by measuring the clearance between the
top surfaces of 2 apex seals with a feeler gauge. Replace all 3 seals
if clearance exceeds .0024" (.06 mm). See Fig. 15.

1.1L ROTARY

Article Text (p. 11)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 04:57PM

Fig. 15: Apex Seal Warpage
Replace if the clearance exceeds limits.

3) Using a feeler gauge, check gap between apex seal and
groove in rotor. Feeler gauge should be inserted until tip of feeler
gauge reaches bottom of groove.
4) Standard clearance is .0020-.0035" (.05-.09 mm). Replace
apex seal if gap exceeds .0059" (.15 mm). Check seal spring height as
shown in Fig. 16. Replace spring if free height is less than .2165"
(5.5 mm).

Fig. 16: Measuring Free Height of Apex Seal Spring
Height must be more than .2165" (5.5 mm).

Side Seal
1) Remove all carbon from side seal and spring. Check side
seal protrusion from rotor surface, and confirm free movement by
pressing with finger. Protrusion should be more than .02" (.5 mm).
2) Check gap between side seal and groove with a feeler
gauge. Standard gap is .0012-.0031" (.03-.08 mm). If wear limit of .
004" (.10 mm) is measured, replace side seal.
3) Check gap between side seal and corner seal with seals
installed on rotor. Insert feeler gauge between end of side seal
(against rotating direction of rotor) and the corner seal. If gap
exceeds .016" (.4 mm), replace side seal.
4) When side seal is replaced, adjust gap between side seal
and corner seal by grinding one end of side seal along round shape of
corner seal, using a fine file. Adjust gap .002-.006" (.05-.15 mm).

Corner Seal
1) Clean carbon from corner seal. Check corner seal
protrusion from rotor surface, and check free movement by pressing
with finger. Protrusion should be more than .02" (.5 mm).
2) Extent of corner seal groove wear is determined by using

1.1L ROTARY

Article Text (p. 12)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 04:57PM

special Bar Limit Gauge (49 0839 165) shown in Fig. 17, and is
classified according to the following.

Fig. 17: Checking Corner Seal Groove Measurement
Replace rotor if both ends of gauge fit in gap.

3) If neither end of gauge goes into groove, it indicates
that gap conforms to specifications. If "Go" end of gauge goes into
groove, it indicates that gap is more than standard, but less than
wear limit. In this case replace corner seal. See Fig. 18.

Fig. 18: Measuring Clearance of Apex, Side & Corner Seals

4) If both ends of gauge (both the "Go" and "No Go" ends) fit
in groove, it indicates that gap exceeds wear limit. Replace rotor.

Eccentric Shaft
1) Thoroughly clean eccentric shaft in a cleaning solution
and blow out oil passages with compressed air. Inspect shaft for
scratching or scoring of bearing journals and possible blocked oil
passages.
2) Check rotor bearing clearance by measuring inner diameter
of the rotor bearing and outer diameter of the eccentric shaft rotor
journal. Clearance should be .0016-.0031" (.04-.08 mm).
3) Replace the bearing if clearance exceeds .0039" (.10 mm).
Replace eccentric shaft if journal diameters are under specified
limits.
4) Place eccentric shaft in 2 "V" blocks. Mount a dial
indicator and check runout of both ends by rotating shaft slowly. If

1.1L ROTARY

Article Text (p. 13)

1983 Mazda RX7

For www.iluvmyrx7.com

Sunday, August 26, 2001 04:57PM

runout exceeds .0024" (.06 mm), replace shaft.
5) Oil passages in eccentric shaft are sealed by a blind plug
in rear of shaft. Inspect plug for possible oil leakage. If leakage is
detected, remove plug with an Allen wrench, and install new "O" ring.
Tighten plug.
6) Inspect needle bearings in end of shaft for wear or
damage. Check for spring weakness, stuck, or damaged steel ball at the
oil jets. Inspect front needle bearing, bearing housing, and thrust
plate for wear or damage. Inspect front and rear oil seals for leaks,
replace as necessary.

REASSEMBLY

Oil Seals
1) Place the rotor on rubber pad or cloth. Install oil seal
springs in their respective grooves on rotors, with each edge of
spring fitted in stopper hole.
2) Ensure oil seal springs have been painted in cream or blue
color: Cream colored springs must be placed on front edge faces of
rotors and blue springs on rear faces of rotors. When installing,
painted side of spring must face oil seal (upward). See Fig. 19.

Fig. 19: Installing Oil Seal Spring on Rotor
Painted side of spring must face oil seal.

3) Insert new "O" ring in each oil seal. Install inner oil
seal to each side of rotor as follows: Position oil seal to groove so
square edge of spring fits in stopper notch of oil seal. Press into

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