3rd Generation RX-7 TSB (Technician Service Bulletin) list - Older
Last Updated November 1, 1995



TSB LIST FOLLOWS:

1. Glove box light fails to go out
2. Power window makes clunk after opening all the way
3. Noise from steering or suspension
4. Black finish peeling from interior trim
5. Noise from the rear hatch hinges
6. Squeaking sound from hood
7. Whistling noise from windshield molding
8. Wind noise from the door windows
9. Correction to owner's manual (alarm system)
10. Fuel injector cleaner
11. Rx-7 fails state emission inspection
12. Engine stalls during warm-up / idle fluctuation
13. Clutch slippage / premature clutch wear
14. Hold indicator light flashes
15. Wheel center cap sticks out
16. Installation of tie-down hole plugs
17. Hesitation at 3000 rpm
18. Air duct pops off turbo or intercooler
19. Squeaking noise when opening or closing door
20. 5th gear shifting noise / grinding
21. Rattle or vibration under car at certain rpms (unofficial)
22. ***RECALL: ENGINE COMPARTMENT CATCHES FIRE WITHOUT WARNING
23. Paint chips on hood, roof, and other body panels
24. Unlocking code for locked anti-theft radio
25. Air pump failure due to installation of non-genuine air cleaners
26. ***RECALL: FUEL LEAKAGE - MORE ENGINE FIRES
27. More details on 3000 rpm hesitation
Summary
a. Author's Comments



1. GLOVE BOX LIGHT FAILS TO GO OUT.

Service bulletin #04293 Category S, issued 10/21/93
Replace lamp cover with modified design part # FD0164170A



2. POWER WINDOW MAKES CLUNK AFTER OPENING ALL THE WAY.

Service bulletin #031/93 Category S, issued 6/16/93
Replace rubber stopper with modified design part # FD0158565



3. NOISE FROM STEERING OR SUSPENSION.
The steering or suspension makes a clunking sound at low speeds or when wheel turned lock to lock.
There are three service bulletins which address this problem:


Service bulletin # 00493 Cat. R, issued 5/19/93, revised 9/22/93
Replace upper A-arm bushings with Part # FD0134480A.
2 bushings per side


Service bulletin # 002/93 Category B, issued 2/26/93
Applies to vehicles with a VIN of JM1FD3***P0207061 or lower produced through May 31, 1992.
Replace engine mount with modified part # FD01 39 040C.
Although the part has been modified, the part # is the same as the original.
Clearance increased between rubber mount and mount housing.


Service bulletin # 00293 Category N, issued 10/21/93
Replace steering rack boots with modified parts.
Left side: part # FD0132125A
Right side: part # FD0232125A



4. BLACK FINISH PEELING FROM INTERIOR TRIM.
Service bulletin #056/92, Category S, Issued 12/15/92
Applies to vehicles with a VIN of JM1FD331**P0207441 or lower produced through August 4, 1992.
Some vehicles may experience the black finish peeling from the following interior trim parts:

(Note from DSZ: Owner Rob Zeitinger experienced this problem on his car with VIN#JM1FD3311**P0207925.
Thus the problem may affect more vehicles than Mazda indicates in the TSB)

FD01 55 210B 00 Center Panel (Holds the radio and climate controls)
FD01 55 420E 00 Meter Hood (Holds all the gauges)
FD01 64 471D 00 Switch Panel (For 5-speed manuals, I think)
FD01 68 4LY 00 Switch Panel (For automatics, I think)
FD01 68 4M0A 00 Arm rest trim lid (L)
FD01 69 44XA 00 Front Assist Grip (R)

Replace the parts under warranty.
The adhesive has been strengthened.
For 1994 models, the parts were redesigned again so there is no extra layer to peel off.



5. NOISE FROM THE REAR HATCH HINGES
Service bulletin #010/93, Category S, issued 2/26/93
Applies to vehicles with a VIN of JM1FD****P0210513 or lower produced through November 30, 1992.
Noise may be heard from the rear hatch hinges when driving over bumps or rough roads.
Replace both the rear hatch hinges with a modified part under warranty.
New Part#: FD01 62 210C
Old Part#: FD01 62 210A



6. SQUEAKING SOUND FROM HOOD
Service bulletin #057/92, Category S, issued 12/15/92
Applies to vehicles with a VIN of JM1FD33**P0208750 or lower produced through July 2, 1992.
After July 2, the hood was modified to eliminate this condition.
Install a washer (Part# FDY1 56 788) under both cushion rubbers under the front of the hood.
If the hood is replaced with a modified part (like if you crashed!) then the washers do not need to be installed.



7. WHISTLING NOISE FROM WINDSHIELD MOLDING
Service bulletin #049/92, Category S, Issued 10/5/92
Applies to vehicles with a VIN of JM1FD331*P0207061 or lower produced through May 31, 1992.
Some RX-7s may emit a whistling noise around the windshield area when being driven at high speeds.
Caused by air being pulled through the space between the molding and the windshield.
A repair seal foam kit has been designed to fix this.
Simply slide the foam under the windshield molding.
Later RX-7s have the sealing foam attached to the windshield molding at the factory.
Repair Seal Foam Kit - Part# B001 77 739



8. WIND NOISE FROM THE DOOR WINDOWS
Service bulletin # 002/93, Category S, Issued 2/5/93
Applies to vehicles with a VIN of JM1FD3***P0205708 or lower produced through April 30, 1992.
Wind noise from the right and left door windows (near the outside door handles).
This is due to air entering the cabin because the windows do not fit flush against the glass channel.
Replace front glass guides with modified part under warranty.

Front Glass Guide (R) - New Part# FD01 58 601B
                         Old Part# FD01 58 601A

Front Glass Guide (L) - New Part# FD01 59 601B
                         Old Part# FD01 59 601A



9. CORRECTION TO OWNER'S MANUAL (ALARM SYSTEM)
Rather than fix a bug in the RX-7 alarm system, Mazda decided to issue a sticker to be placed in your owner's manual.

Service bulletin # 003/93, Category AD, Issued 3/8/93
Applies to 1993 RX-7 with VIN of JM1FD331*P0207440 or lower Dealership is supposed to put the following stickers in your owner's manual:
{Attach sticker to lower right side of page 2-10}

How to Arm the System for vehicles produced up to June 7, 1992 the following procedures apply
1. Stop engine
2. Remove key from ignition switch. See NOTE
3. Open door. Exit vehicle.
4. Close and lock driver's side door. Passenger door and hatch will lock automatically.
5. Center console indicator light will light for 10 seconds, then will continue to flash every 3 seconds.
System is armed.

NOTE: If any of the doors, hood and/or hatch are opened prior to removing the key from the ignition switch, the theft deterrent system will not arm.
The following procedure should be done to arm the system:

{Attach sticker to Page 2-11}
Same as above with different note to apply to vehicles made after June 7, 1992.

To order stickers (if your dealer doesn't have them), send fax to
MAZDA MOTOR OF AMERICA, INC.
SUPPORT SERVICES DEPARTMENT
ATTN: SERVICE PUBLICATIONS COORDINATOR
FAX# (714) 454-7010

Be sure to list bulletin # 003/93 Category AD and specify how many stickers you want.



10. FUEL INJECTOR CLEANER
Service bulletin #001/93, Category F
Applies to all fuel injected models to improve fuel injection performance, Mazda has tested and approved a highly effective fuel injector cleaner.
The kit and cleaner is recommended for all Mazda fuel injection systems.
Mazda's fuel injector cleaner uses a chemical reducing agent rather than the common solvent used in typical aftermarket cleaners.
As a result, in tests against aftermarket competitors, Mazda's cleaner outperformed all others and was the only one to restore the fuel injector's flow rate to original factory specs.
Mazda recommends cleaning injectors every 15,000 miles.

DESCRIPTION              PART#              REMARKS
Fuel Injector Cleaner     0000 77 2019       case of 12 cans

Tool kit                  0000 77 2026       w/ instructions
                           (req'd for use with the cleaner)

Service brochures        9999 95 043N 92    QTY: 1 package = 50 brochures



11. RX-7 FAILS STATE EMISSION INSPECTION
Service bulletin # 005/93, Category F, issued 4/28/93
Applies to all RX-7s
Some vehicles with properly functioning emission control systems may fail emission inspections.
In order to avoid this, the following must be done prior to the test:
1. Engine should be warmed up but not overheating
2. All electrical loads and A/C should be turned off
3. For 5-speed models: Neutral range should be selected
4. For AT models: (N) or (P) range should be selected
5. Before testing, bring engine operating temp to normal by operating the engine for 3 minutes at 2500 - 3000 rpm.
6. Test the vehicle as soon as possible after the engine has warmed up.



12. ENGINE STALLS DURING WARM-UP / IDLE FLUCTUATION
Service bulletin #032/92, Category F, issued 12/23/92
Applies to 1993 RX-7 5-spd models with VIN of JM1FD3312P0208703 or lower produced through July 2, 1992.
Applies to 1993 RX-7 automatics with VIN of JM1FD331XP0210513 or lower produced through September. 30, 1992.

Some 1993 RX-7 vehicles may experience stalling during deceleration with the throttle released approaching a stop.
This occurs during initial warm-up and, sometimes after the car has reached operating temperature.
Also, when idling with the A/C on, engine speed decreases as the A/C compressor engages and idle fluctuation may occur.
The ECU has been modified as a countermeasure.
The modified ECU is designed to:
1. Make air/fuel ratio adjustments to maintain stable idle at all temperatures
2. Turn off the A/C compressor when the clutch pedal is depressed or when the accelerator pedal is released.

(WARNING from DZ: The following parts may have been superseded by a more recent TSB.
Have your Mazda dealer check their own TSB list which should be more up to date.)

Replace ECU under warranty with following part:
N3A1 18 881R ECU (Federal 5-speed)
N3A2 18 881R ECU (Federal Automatic Transmission)
N3A3 18 881R ECU (California 5-speed)
N3A4 18 881R ECU (California Automatic Transmission)



13. CLUTCH SLIPPAGE / PREMATURE CLUTCH WEAR
Service bulletin # 001/93, Category H, issued 12/17/93, revised 94
Applies to 1993 RX-7 with a VIN of JM1FD333*P0200001 through JM1FD333*P0299999.
Applies to 1994 RX-7 with a VIN of JM1FD333*R0300001 through JM1FD333*R0300031.

Customers with the following driving habits may experience clutch slippage or premature clutch wear:
1. Starting from stop in 2nd gear
2. Hard acceleration

To improve the clutch for these conditions, the facing material of the clutch disk has been changed.
These changes have been used in production since October 8, 1993.

Old Part# N315 16 460A
New Part# N315 16 460C



14. HOLD INDICATOR LIGHT FLASHES
Service bulletin #012/92, Category K, issued 7/15/92
Applies to 1993 RX-7 built prior to May 11, 1992

If the hold light starts flashing while the vehicle is running, and torque reduction control fail code is 57, replace ECU under warranty.

New Part# N3A2 18 9E1B
Old Part# N3A2 18 9E1



15. WHEEL CENTER CAP STICKS OUT
Service bulletin #003/92, category Q, issued 9/14/92
Applies to vehicles built prior to Feb. 10, 1992 up to VIN JM1FD331*P0201892

Some vehicles may have aluminum wheel center caps that do not fit flush with the wheel.
This is caused by contact between the cap and the axle flange.
Replace center cap with modified part under warranty.
New Part# FD01 37 191B
Old Part# FD01 37 191A



16. INSTALLATION OF TIE-DOWN HOLE PLUGS
Service bulletin #050/92, Category S, issued 10/19/92

Tie-down hole plugs need to be installed on vehicles produced after May 20, 1992.
These tie-down holes are used during transport.
The plugs will prevent water from penetrating the body which will result in rust.
These plugs should have been installed by your dealer.
The 4 holes are located behind the front wheels about 10 inches from the side of the car and in front of the rear wheels about 4 inches from the side of the car (underneath the car).



17. HESITATION AT 3000 RPM
Not a TSB. Published in January 1994 Mazda Tips (Dealer newsletter)

A kink in the turbo charger relief valve vacuum hose may also cause the engine to lack power or hesitate during acceleration.
Check the hose and replace it with a modified one if it is kinked.
The new part is available at the PDC (part # N3A3-20-341A)



18. AIR DUCT POPS OFF TURBO OR INTERCOOLER
Not a TSB. Published in January 1994 Mazda Tips (Dealer newsletter)

Turbo pressure can cause the air duct to come loose.
Result: the vehicle loses power or the engine produces a sucking noise.
Mazda has made the following modifications to correct this condition:

A. Rubber mount washer - changed with flange type
   Part #FE51-13-329
     (affected VIN - JM1FD331*P0207547 - 6/10/92)

B. Rubber joint - material changed (starting in 1994)

C. Intercooler air hose - material changed
     (Affected VIN - JM1FD331*P0209102 - 7/10/92)

D. Air duct tightening torque (hose clamps) increased to 70 kg/cm2 (starting in 1994)

These modified parts are available at the PDC.
If you encounter this condition, replace the existing parts with the modified ones.



19. SQUEAKING NOISE WHEN OPENING OR CLOSING DOOR
Service bulletin #010/94 Category S, issued 2/11/94
Applies to vehicles with a VIN of JM1FD33**P0200001 through P0210664
(No date specified, but this was probably fixed in February 1993)

When opening or closing the door a squeaking sound may be heard.
This is caused by the door checker.
To correct this problem, the checker has been modified.
Replace part under warranty.

New Part#: FD01 58 270B
Old Part# FD01 58 270A

If both door checkers are replaced, 2 warranty claims will be required.



20. 5th GEAR SHIFTING NOISE / GRINDING
Service bulletin # 001/94 Cat. J, issued 1/7/94, revised 1/27/94
Applies to vehicles with a Vin of JM1FD332*P0100001 through 210508

If grinding occurs when shifting to 5th gear, a 5th gear synchronizer ring, damaged by mis-shifting, may be the cause.
To correct this concern, the shift select spindle has been modified to increase the accuracy of the shift pattern.

(Note from DZ: they raised the spring force from 6.7 kg to 8.9 kg on the shift select spindle)

Replace shift select spindle with Part# R503 17 550 and replace 5th gear synchronizer with Part# W501 17 725B.
Inspect related parts for damage and replace as necessary.
Applies to all vehicles under normal warranty.



21. RATTLE OR VIBRATION UNDER CAR AT CERTAIN RPMS

This is not a TSB yet but I suspect it will become one soon.
A number of 1993 RX-7 owners have reported hearing a rattle or vibration under the car which is more pronounced at certain RPMs.
The problem is that the bolts which retain the heat shield to the catalytic converter have corroded resulting in a loose shield.
Mazda sells the cat/heat shield assembly only as a unit, so the entire catalytic converter must be replaced.
This is a warranty item.



22. RECALL: ENGINE COMPARTMENT CATCHES FIRE WITHOUT WARNING
Affects 1993-1994 RX-7 models manufactured before Dec. 21, 1994.
Beginning in 1993, a number of RX-7s burst into flames without warning.
The NHTSA investigated and concluded in a report by Jeff Quandt that turbocharger malfunctions were to blame for the fires.
(A free copy of report #PE94-009 may be obtained by calling the NHTSA hotline on 1-800-424-9393)
Mazda redesigned the turbo charger housings on August 1, 1993 but claimed in a letter to the NHTSA that the redesign was simply to make the turbocharger housings easier to manufacture.
Mazda conducted their own investigation on four test cars and concluded that the fires were caused by leaks in the cooling system.
They claimed that coolant pooled on top of the engine, became concentrated by boiling, and then caught fire as it dripped onto a hot exhaust.
The fact that a recall involving the cooling system cost Mazda a few hundred dollars per car versus a few thousand dollars for turbo charger replacement may have had something to do with their claim.
The text of the recall letter follows:


1993-94 RX-7 Coolant Leak [Recall Campaign #54407]
Dear RX-7 Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Mazda has determined that a defect which relates to motor vehicle safety exists in certain 1993-94 RX-7 models.
We have decided to conduct Recall Campaign #54407 for replacement of selected engine cooling system components in those vehicles, beginning August 8, 1994.

If your RX-7 has been subjected to high-speed operation and then parked before cooling down, the residual engine heat combined with build-up of pressure in the cooling system can raise the temperature of the coolant to levels where the integrity of the cooling system can be compromised.
Repeated operation of the vehicle in this manner may produce cooling system leaks.

Under some circumstances, the leaking coolant mixture can collect on top of the engine, where some of the water can evaporate, increasing the concentration of the coolant.
If coolant then leaks onto the exhaust manifold, an engine compartment fire could be the result.

Your RX-7 is equipped with a water level sensor that warns you of low coolant levels with both a warning light and accompanying buzzer.
In most cases, you would be warned of a low water level prior to the point where enough coolant had been leaked to present any serious risk of fire.

Please make an appointment at your Mazda dealer to have the required repairs performed at no charge to you.

If you have moved or no longer owned the vehicle, please complete the enclosed "Change of Address/Ownership" pre-paid postcard as soon as possible, so we may update our records and/or notify the current owner.

Should you have any questions regarding this program, please contact our Customer Relations toll-free number (800) 222-5500.

If your dealer or distributor does not remedy the defect without charge within a reasonable amount of time, you may wish to notify the Administrator, National Highway Traffic Safety Administration, Washington, DC 20590, or you can call their toll-free Auto Safety Hotline at (800) 424-9393, (residents of Washington, DC may call 366-0123).

Our goal at Mazda is to build and maintain only the highest quality products.
Please accept our apologies for any inconvenience this may cause you.

Sincerely,


Mazda Motor of America, Inc.



:
Despite the assurances in the recall letter, none of the RX-7 fires which the NHTSA investigated involved automobiles "subjected to high-speed operation" nor were the owners warned by a light or buzzer that the coolant level was low.
At least two fires resulted in the loss of the owners' homes although to this date, no injuries or deaths have been reported.
Until your RX-7 has had the recall service performed, it would be advisable NOT to park it in an attached garage or next to anything valuable.



23. PAINT CHIPS ON HOOD, ROOF, AND OTHER BODY PANELS
This is another one of those RX-7 problems which is not documented in an official TSB but is being treated by Mazda on a case by case basis.
RX-7 models painted Vintage Red, Montego Blue, or Black are most susceptible to this problem.
Small paint chips start to appear on the hood, around the headlight openings, on the leading edge of the roof, and around the wheel arches.
The problem is caused by a lack of adhesion between the paint and the primer and is made worse by the fact that the primer is white in color.
In order to properly fix this problem, the entire car must be stripped down to bare metal, reprimed, and then repainted.
In most cases Mazda can be convinced to pick up the tab for this expensive job ($5,000 - $7,000) without having to hire a lawyer.
What follows are general guidelines for getting this problem fixed:

A. Call Mazda Customer Relations on 1-800-222-5500 and describe the problem to them.
They will create an electronic file on your case which will be sent to your dealership.
Your dealership is required to resolve the problem (somehow) and report back to Mazda within a certain number of days.
Write down the file number so you can check back with Mazda in a week or so to see how they closed the file.
My dealership tried to scam the system by reporting that they were "unable to locate the customer" even though I purchased the car from them and lived less than 2 miles away.
(And I knew everyone there on a first-name basis!)

B. If you don't hear from your dealership within a couple of days, then call them and ask to speak to the service manager.
Explain the paint problem to him/her and ask to have something done about it.
This is where the Mazda District Manager (DM) gets involved.
He is authorized to make deals on cases involving flawed paint.
The dealer will schedule a time for you, your car, and the DM to meet.
Most likely, it will be an inconvenient time, but try to be flexible.
The DM is a hard person to track down.

C. On the day you meet the DM, make sure the car is clean and appears to be well taken care of.
The DM will probably look at the paint chips with a magnifier and declare that each chip has a clearly visible impact mark.
He may also look at the windshield and declare that there are "chips" missing from the glass.
(All cars have little chips in the windshield! Check this out next time you are in a parking lot.)
Thus the damage is due to stones and is NOT covered by warranty.
Do not despair.
Tell the DM that your car has seen normal service and this type of paint damage is unacceptable for a $35,000 car.
Always be polite and DO NOT lose your temper.
If the offer of a repaint is not made, then start to play your cards one by one.
First, explain to the DM that you are aware of the "adhesion problem" with the RX-7 paint and you know that Mazda has agreed to fix this problem "as a courtesy" for many 1993 RX-7 owners.
If he still doesn't budge, show him a list of RX-7 owners who have had their car repainted by Mazda and let him know you are providing a copy to your lawyer.
(If you email me a request on zeck@hodcs.ho.att.com, I can send you my current list.)

D. By this time, they will probably be offering to repaint the "affected areas" at no charge to you.
If they don't, it's time to see a lawyer.
If they do, you need to remember that the problem won't be fixed unless the car is stripped down to bare metal.
Unless you want a 2-tone car, you should insist that they paint all of it and not just the parts which have chipped.

E. After they have agreed to repaint the car, they may ask you to agree in writing that this is a one-time courtesy fix and you may never make another paint claim.
It's fine to sign something like this, but only AFTER you have approved the final paint job.

F. Make sure you visit the body shop where the work will be done.
Introduce yourself to the manager and ask to receive copies of any paperwork which describes the work performed.
This will protect you from Mazda attempting to just have another layer of paint slapped on top of the old layer.
Slip the manager a nice tip ($50 - $100) to take extra care of your car and see that everything is done right.

G. Enjoy your car!



24. UNLOCKING CODE FOR LOCKED ANTITHEFT RADIO

If power is removed from the radio in the 3rd generation RX-7 and the anti-theft feature has been activated, the radio will blink "CODE".
If three attempts to enter the code fail, the radio locks up and blinks "ERR" and becomes unusable.
Bugs in the radio software may cause it to go directly to the "ERR" state.
A "secret" code is available which will allow the radio to be unlocked.
For obvious reasons, I will not post this code to the internet.
If your radio ever locks up and you need assistance getting it unlocked, send me email with the following information:

Name
Address
Phone Number
VIN# of RX-7

I will contact you and provide you with instructions for unlocking your radio.
I will also keep a record of who I give this information to.
Please do not forward it to anyone or post it to the internet.
If you do not agree to these terms, you may go to your Mazda dealer and have them unlock the radio for you for a nominal charge (unless the car is under warranty).



25. AIR PUMP FAILURE DUE TO INSTALLATION OF NON-GENUINE AIR CLEANERS
Applicable Models: 1993-95 RX-7
Bulletin No. 006/95
Issued: 4/5/95

Installing non-genuine air cleaners may lead to air pump failure.
Unlike the original design, non-genuine air cleaners draw heated, engine compartment air into the air pump.
This air increases pump temperature which may result in lubrication loss and bearing failure.
Customers should be informed that the vehicle warranty prohibits alteration of the emission control system as well as other components.
Recommend that the customer have the original air cleaner installed to prevent non-warrantable component failure.



26. FUEL LEAKAGE RECALL - ENGINE FIRES
CAMPAIGN #60504

The problem is that fuel lines become brittle because of excessive engine compartment temperatures.
Eventually, they leak fuel and the car catches fire.
The recall involves replacing the fuel lines with a different material and adding a fan control relay which runs the cooling fan for 10 minutes after the engine is shut off.

Affects:
All 1993 RX-7 models manufactured beginning December 1, 1991
and 1994 RX-7 models manufactured through September, 1994.

VINs affected:
JM1FD33**P0200001 - JM1FD33**R0303550

Total number of affected vehicles: 13,400
Repair Time: 3.8 hours

Install Part #s
N3A1-18-SE0 Fan Control Kit
N3A1-13-S70 Fuel Hose Kit

The following is a portion of a letter from the Vice President of Mazda North America to the NHTSA dated March 30, 1995:

Mazda first learned of an engine compartment fire in an RX-7 which had the recall remedy conducted in November, 1994.
In January, 1995, Mazda engineers investigated seven RX-7 engine fires in the United States and in the same month, NHTSA's information request on the completion rate for the on-going safety recall campaign was issued.

Mazda submitted a partial response on February 8, 1995 and a complete response on February 22, 1995 in which Mazda reported that it knew of 18 fire cases in which investigations in the U.S. found evidence of fuel seepage from the fuel hoses on those vehicles.
In order to identify the cause of the fuel seepage, thorough investigations and analyses have been conducted.

In March, 1995, Mazda identified the cause of fuel seepage and reported it to NHTSA on March 22, 1995.
Mazda concluded on March 24, 1995 that a defect existed and that a recall was required.

Mazda Motor Corporation will notify all subject vehicle owners by letter and will install an additional control unit for the electric cooling fan.
The fan activates after the engine is turned off when the coolant exceeds a specified temperature.
Mazda will also replace the fuel hoses with modified hoses in all these vehicles without charge.

Sincerely yours,


Shintaro Nakatsuka Vice President and General Manager



The following is the text of the recall letter which should be going out to owners in May 1995:

1993 and 1994 RX-7 Fuel Leakage [Recall Campaign #60504]

Dear Mazda Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Mazda Motor Corporation has determined that a defect which relates to motor vehicle safety exists in certain 1993 and 1994 Mazda RX-7 models.

If an RX-7 is driven under severe conditions (e.g. high speed and uphill driving), and the engine is turned off, the temperature of the engine compartment rises due to the residual engine heat.
This condition may cause premature deterioration of the fuel hoses' elasticity.
Repeated vehicle operation in this manner may lead to a reduction in the sealing performance of the fuel hoses and in rare cases can result in engine compartment fires.

We have made arrangements for you to have the engine fuel hoses replaced and the engine cooling fan control system modified, free of charge, at an authorized Mazda dealer.
The necessary work takes approximately three hours to perform.
To minimize your inconvenience, we recommend that you schedule an appointment with a Mazda dealer to have this work performed.

If you have moved or no longer own the vehicle, please complete the enclosed Change of Address/Ownership pre-paid postcard as soon as possible.
This enables us to update our records and notify the current owner, if necessary.

Please note the following change in the operation of the cooling fan after the recall repair is performed:

Once the engine coolant exceeds a preset temperature, the cooling fan will come on and continue running for about 10 minutes after the ignition switch is turned off.
Before the service, the cooling fan would stop when the ignition switch was turned off.

Should you have any questions regarding this program, please contact our Customer Relations toll-free number (800) 222-5500.

If your dealer or distributor does not remedy this defect without charge and/or within a reasonable amount of time, you may wish to notify the Administrator, NHTSA, Washington, DC 20590 or you can call their toll-free Auto Safety Hotline at (800) 424-9393. (Residents of Washington, DC may call 366-0123).

Our goal at Mazda is to build and maintain only the highest quality products.
Please accept our apologies for any inconvenience this program may cause you.

Sincerely,


MAZDA MOTOR OF AMERICA, INC.



27. MORE DETAILS ON 3000 RPM HESITATION
There are numerous "fixes" out there including Engine Control Unit (ECU) replacements, check valve replacement, kinked vacuum hoses (See TSB item #17), replacement of the EGR valve with the California EGR valve, etc.
While these may help reduce the symptoms, on most RX-7s the problem will remain.
There was even an internal Mazda fix which included the adjustment of a rod that controls the "transition" between the primary and secondary turbos, but again, just a bit of help, not a true "fix".

The problem seems to be the programming in the factory computer.
The RX-7 has two secondary injectors which turn on at aprox 2,700 RPM.
While the engine RPMs are rising under light acceleration, the secondary injectors will turn off for a fraction of a second, then turn back on.
This seems to be causing a momentary lean condition which we experience as the infamous "3,000 RPM hesitation".

The secondary injectors are controlled by the ECU at terminals 4 X and 4 Z.
By hooking up a digital multi-meter to these terminals and observing the voltages going to the injectors, we may observe this problem directly.
At about. 12.5 Volts, the injectors are off.
At lower voltages, they are being switched on at varying rates based upon the programming of the ECU.
Every time the engine hesitates while going through the 3000 RPM range, we may observe the secondary injectors being switched off, engine hesitation, then injectors back on, hesitation gone, and normal acceleration.
It is possible that the only true fix is to reprogram the ECU to keep the secondary injectors from switching off in the 3,000 RPM range.
Will Mazda address this problem in an upcoming release of the ECU?
Possibly, but only if enough customers continue to complain about the 3,000 RPM hesitation.
Contact your dealer service department and also call the Mazda Customer Relations number on (800) 222-5500.



Summary of running changes on the Mazda assembly line:
(Assembly month/year printed inside driver's door)

<1993 Models>
Dec. 1, 1991: First 1993 RX-7 rolls off the assembly line

Feb.10, 1992: Redesigned wheel center caps

Apr. 30, 1992: Redesigned front glass guide (power windows)

May 11, 1992: Redesigned circuit logic of torque reduction control

May 20, 1992: Tie down holes underneath cars added for ease of transportation. Dealer must install hole plugs to prevent rust.

May 31, 1992: Redesigned upper A-arm bushings, modified front windshield molding, redesigned engine mount, redesigned steering rack boots

June 7, 1992: Redesigned alarm to function if door opened before engine stopped

June 10, 1992: Flange added to rubber mount washer for intercooler hose. The old washers break apart.

July 2, 1992: Redesigned ECU for 5-speed RX-7, redesigned hood to prevent squeaking

July 10, 1992: Redesigned intercooler hose with stronger material

Aug. 4, 1992: Redesigned black interior trim pieces to prevent peeling (Although some cars produced after this date have experienced the peeling trim problem)

Sep. 30, 1992: Redesigned ECU for Automatic Transmission RX-7

Nov. 30, 1992: Redesigned rear hatch hinges

Dec. 2, 1992: Redesigned shift select spindle to increase accuracy of shift pattern and prevent damage to 5th gear synchros due to missed shifts

<1994 Models>
Feb. 10, 1993: Redesigned turbo relief vacuum hose (3000 rpm hesitation), redesigned door checker, redesigned steering rack boots (larger diameter) redesigned glove box lamp cover (light stayed on with door closed)

Aug. 1, 1993: Redesigned turbo charger housing (Mazda says this was to make the part easier to manufacture.)

Oct. 8, 1993: Redesigned clutch facing material for longer life

Jan. 21, 1994: Redesigned following cooling system parts:

                           old -> new            old -> new
PART NAME                   MATERIAL              DESIGN TEMP(C)

Water pump mech. seal      NBR -> EPDM            125 -> 150
Water level sensor         Polyacetal -> PPS      125 -> 200
Radiator upper hose        Polyester -> Nylon     130 -> 150
Filler cap                 NBR -> EPDM           130 -> 150
Filler cap body            Nylon -> Aluminum      130 -> 235
Thermostat gasket          NBR -> EPDM            125 -> 150
Water hose(throttle body) Polyester -> Nylon     130 -> 175
Water hose(sep tank)       Polyester -> Nylon     130 -> 150

ALL CARS BUILT BEFORE THIS DATE ARE SUBJECT TO A FACTORY RECALL TO PREVENT ENGINE COMPARTMENT FIRES.

Mar. 23, 1994 Redesigned radiator cap. Pressure lowered from:
                1.3 +/- 0.15 kg/cm/cm to 0.9 +0.25 kg/cm/cm
                                               -0.05

Sept, 1994 Redesigned fuel hoses to withstand higher temperatures and added fan relay to allow cooling fan to run for 10 minutes after engine was shut off

ALL CARS BUILT BEFORE THIS DATE ARE SUBJECT TO A SECOND FACTORY RECALL TO PREVENT ENGINE COMPARTMENT FIRES.




8 Apr, 1996

After working for over three months, I have finally been able to get TSB listings directly from Mazda.
I now have TSBs exactly as the dealerships get them, complete with illustrations.
This is much better information than is available through services like AllData.

The "old" version of this list will be replaced by the new version as I type in the TSBs.
- Troy


14 Feb, 1996

Please note that the ownership of this list has recently changed.
All correspondence regarding the TSB list should now be directed to: tcw@amicus.com

This list is slightly out-of-date, but will be updated soon.
A general announcement will be made when this is done.

Many thanks go to Dave Zeckhausen, for his service to the online community of RX-7 owners in maintaining this list.
- Troy



written by: Troy (
tcw@prismnet.com)
http://www.k-rad.com/tsblist

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