RX7 rebuild - number 2!!

[Iain C]

wow Mr fish thats fantastic!
Dont know how people go about doing something like this.
I cant change my headlights a the mo let alone rebuild the engine!
I look forward to the updates.

[Bobfish]

hey guys, sorry i havent posted in a while, been too busy working on the car!

heres the progress from the weekend and tonight...

Well heres the front rotor cleaned up..



But look, disaster!!! A coolant seal broke...crappy mazda castings!!



Luckily i had a spare on hand...so i got to work scraping out those grooves of 14 years worth of crap, and ended up with this...



Time to measure it all up...



Front plate:

No warping.
Side seal wear - 0.03mm, mazda spec <0.1mm
side seal overlapping oil seal wear - N/a, Mazda spec <0.01mm
Side seal outside oil seal wear - 0.02mm - Mazda spec <0.1mm
Oil seal wear - N/a - Mazda spec 0.02mm

Intermediate plate, front side

No warping.
Side seal wear - 0.04mm, mazda spec <0.1mm
side seal overlapping oil seal wear - N/a, Mazda spec <0.01mm
Side seal outside oil seal wear - 0.02mm - Mazda spec <0.1mm
Oil seal wear - N/a - Mazda spec 0.02mm

Intermediate plate, rear side

No warping.
Side seal wear - 0.03mm, mazda spec <0.1mm
side seal overlapping oil seal wear - N/a, Mazda spec <0.01mm
Side seal outside oil seal wear - 0.02mm - Mazda spec <0.1mm
Oil seal wear - N/a - Mazda spec 0.02mm

Rear plate

No warping.
Side seal wear - 0.02mm, mazda spec <0.1mm
side seal overlapping oil seal wear - N/a, Mazda spec <0.01mm
Side seal outside oil seal wear - 0.02mm - Mazda spec <0.1mm
Oil seal wear - N/a - Mazda spec 0.02mm

Eccentric shaft:

Front side outside shaft bearing external - 42.95mm
Front side outside eccentric gear bearing internal - 43.03mm
Clearance - 0.08mm - Mazda spec 0.06-0.11mm

Front side inside shaft bearing external - 42.97mm
Front side inside eccentric gear bearing internal - 43.03mm
Clearance - 0.06mm - Mazda spec 0.06-0.08mm

rear side outside shaft bearing external - 42.95mm
rear side outside eccentric gear bearing internal - 43.03mm
Clearance - 0.08mm - Mazda spec 0.06-0.11mm

Rear side inside shaft bearing external - 42.97mm
Rear side inside eccentric gear bearing internal - 43.03mm
Clearance - 0.06mm - Mazda spec 0.06-0.08mm

Then i dry assembled the rotors:



Ground my side seals...

front rotor gear side:

face1 0.25mm clearnace
face2 0.2mm clearance
face3 0.1mm clearance
Mazda spec 0.05-0.4mm

Front rotor open side:

face1 0.2mm clearnace
face2 0.1mm clearance
face3 0.15mm clearance
Mazda spec 0.05-0.4mm

Rear Rotor Gear side:

face1 0.1mm clearnace
face2 0.1mm clearance
face3 0.15mm clearance
Mazda spec 0.05-0.4mm

Rear toror Open side:

face1 0.2mm clearnace
face2 0.15mm clearance
face3 0.3mm clearance
Mazda spec 0.05-0.4mm

I put all my seals to one side on rotor build sheets...I made 4 of these, one for each side of the two rotors.



Rotors now ready for wet assembly:



My engine build area! lol



Off we go!









And we\'re done!





Flywheel on...



Now to fit all this stuff

[Jit]

Nice one Carl! I was gonna ask i I could drop round and watch...guess its too late for that Actually...i might need to do one thing tho...dyou mind if i drop round and identify label up my loom seeing as yours is correctly done!?

[mullins]

One of those flywheel locking tools is exactly what I need right now! I\'ve tried making my own but each attempt has ended in a twisted lenght of metal!

[Bobfish]

Mullins, for a flywheel loking tool get a length of angle iron from B&Q. It WONT bend, its solid stuff. for an auto drill on hole in the end and fix it with a bolt to the drive plate, then put a bolt through the next hole in the drive plate and just tighten it onto the drive plate with a nut like the photos.

For a manual, measure the distance from one bolt hole to the next little piece of dowel in the flywheel. Drill two holes this distance apart on the angle iron, and use one of the clutch retaining bolts to fix the angle iron to the flywheel and slide the other hole over the dowel.

I can give you the measurement if you dont have calipers.

One2Watch - no problems mate, see you tonight.

[Bobfish]

see photo, i actually used 2 bolts here but you can just slide it over the dowel. Obviously though 2 bolts is more secure.:

[interloper393]

great work im going for this soon, just looking for the right car in japan, importing myself lol.. cn i ask how you cleaned all the engine parts? they look almost new at the end

[Frankie]

Fantastic thread. Bobfish you and one2watch are brave guys for tackling a job of this scale. Makes me feel more confident about doing the same, hopefully not for a while though. And you\'re both local which I\'m sure will come in handy.

One question though, where did you send your injectors for cleaning? How long does it take and do you mind if i ask the cost?

[efiniste]

Where did you get your flywheel puller from Bobfish?

[Bobfish]

Cleaned the engine parts with a brass brush, a screwdriver (for the coolant grooves) and standard engine degreaser solvent.

Injector cleaning i got done at Asnu - its local to me. Got the number from yellow pages. Takes a day and cost me 15 an injector.

Flywheel puller is a draper hub puller. make sure you use something larger than the ID of the shaft to protect your pilot bearing when pullnig though!

P.s NEW DISASTER

OMP line broke on removal. got a new one. wrong one! none of the others IN THE COUNTRY! gonna have to wait till next week. Have from the time i get the new OMP line till friday to finish the engine, reinstall in, remove my engine, fix the oil leak, fit a new rad and get a 4 wheel alignment. Maaan this is gonna be tight!!!

[*Bowsy*]

great thread fella,are you just using blue hylomar on the legs and vaseline on the waterseals to get keep them inplace?.

Also do you have the name of the engine degreaser as the one i have is crap,need to buy some better stuff

[Bobfish]

Blut hylomar on the legs and hylomar on the water seals also to keep them in place. It does a much better job than vaseline at it!

Engine degresear came in a big blue 5l can and is called "hyper clean"

[Jit]

Frankie. My injectors were sent down to reworx who do it for a tenner an injector. However, if id known about asnu, id prolly have taken it there as its definitely closer and from what Carl has said, they sound like they do a sound job.

[Grizzly]

Blut hylomar on the legs and hylomar on the water seals also to keep them in place. It does a much better job than vaseline at it!

Have you had any problems with Oil leaks using Blue Hylomar on the legs???

I was told its too Thin and too use the Sump gasket sealer? (the Grey stuff)

Yeh Vaseline is just for moving parts like Apex\'s and side seals etc so the don\'t drop out.

[Martiny]

Great thread.. keep it up!