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RX-7 Rotary Engine: Engine: Disassembly

NOTE: To ease engine disassembly, manufacturer recommends use of special engine stand (49 0107 680A) and hanger (49 1114 005).
  1. Loosen drive belts and hoses, and remove air pump and alternator. Disconnect metering oil pump connecting rod and hoses at metering oil pump outlets. Remove exhaust manifold cover. Remove intake manifold and carburetor. Remove gasket and "O" ring.
  2. Remove exhaust manifold, engine mount and distributor Remove, oil filter and cover from front housing. Remove water pump and drive pulley for air conditioning compressor (if equipped).
  3. Turn engine over, and remove oil pan and strainer. Install flywheel brake (49 1881 060) on manual transmission models or stopper (49 1881 055) on automatic transmission models.
  4. Remove eccentric shaft pulley. Take off front cover with gasket, and slide distributor gear off shaft. Remove "O" ring from oil passage. Remove oil pump sprocket nut. See Fig 1. Slide oil pump sprocket, eccentric shaft sprocket and drive chain off together. Remove oil pump.
  5. Remove balance weight and following parts in order: Thrust washer, needle bearing, bearing housing, needle bearing, spacer and thrust plate.
  6. On manual transmission models, remove clutch assembly. Use puller to remove flywheel. On automatic transmission models, remove drive plate. Use puller to remove counterweight.
    Fig 1: Oil Pump Drive and Sprocket Removal
    G09332145Courtesy of MAZDA MOTORS CORP.

    Pump drive and sprocket must be removed together. 

  7. Remove tension bolts on rear housing in sequence shown in Fig 2. Loosen in 2 or 3 steps. Lift rear housing off shaft. Remove any seals stuck to rotor sliding surface, and place them back in original positions. Remove seals and "O" rings from face of rear rotor housing.
    Fig 2: Loosening Sequence of Tension Bolts
    G09332146Courtesy of MAZDA MOTORS CORP.

    Loosen in 2 or 3 steps. 

  8. Attach dowel puller (49 0813 215A or equivalent), and pull tubular dowels off rear rotor housing. Hold rotor housing by hand to keep it from moving up, and remove rear rotor housing. Use caution to avoid dropping apex seals and side pieces of rear rotor. Remove seals and "O" ring from front side of rear rotor housing.
  9. Remove side pieces, apex seals and springs from rear rotor and store in order for reassembly. Remove all corner seals, corner seal springs, side seals and side seal springs and store in order for reassembly. Remove rear rotor, and place on clean pad with internal gear side down.
  10. Remove seals and springs on remaining side of rotor, and store in order for reassembly. Place protector on seal inner lip, and remove outer seal with remover (49 0813 225 or equivalent). Remove inner seal. Remove seals and springs and store in order for reassembly. Mark rear rotor for assembly identification.
  11. Attach puller. While holding housing down, pull tubular dowels off intermediate housing. Remove intermediate housing by sliding beyond rear rotor journal on eccentric shaft. Carefully lift out eccentric shaft to avoid damage to rotor bearing and main bearing. Repeat steps  6) through  8) to remove front rotor housing and rotor assembly.
    Fig 3: Extracting Tubular Dowels from Engine
    G09332147Courtesy of MAZDA MOTORS CORP.

    Hold housing down with hand. 

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