Mazda RX7 cooling system specs applies to 1993-1995 FD3S models.

• Coolant Replacement Interval: 30,000 Miles Or 24 Months
• Coolant Capacity: 9.3 Qts. (8.8L)
• Radiator Cap: 11-15 psi
• Thermostat Opens
  • Starts: 176-183°F (80-84°C)
  • Fully Open: 203°F (95°C)

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Automatic transmission removal and installation applies to 1993-1995 Mazda RX7 models.

On Mazda RX7 models with anti-theft radio system, obtain code number from customer to deactivate radio anti-theft system BEFORE disconnecting negative battery cable. To deactivate radio anti-theft system, turn ignition switch to ACC position. Press SCAN and AUTO-M buttons simultaneously until “cod e” is displayed. Press SCAN and AUTO-M buttons again until 4 bars are displayed.

Use preset button No. 1 to enter first number. Use preset buttons No. 2, 3 and 4 to set other numbers. Press SCAN and AUTO-M buttons for about 2 seconds until a beep is heard. After 5 seconds, flashing “cod e” will go away and radio will operate.

Removal

1. Disconnect negative battery cable. Raise and support vehicle. Drain transmission fluid. Remove both undercovers. Remove secondary air injection pipe. Remove front exhaust pipe, heat insulator and catalytic converter. Mark drive shaft-to-differential assembly for reassembly reference.
2. Remove drive shaft. Insert plug in rear of transmission to prevent leakage. Lower vehicle. Support engine from above using proper engine support assembly. Raise vehicle. Remove front, center and rear crossmembers. Support differential with transmission jack. Remove power plant frame (beam connecting transmission to differential). Remove vacuum hose, shift rod and oil cooler lines from transmission.
3. Disconnect speed sensor. Remove starter. Disconnect neutral safety switch connector, 2 speed sensor connectors and solenoid valve connector. Remove dipstick tube. Remove all wiring harness connectors from transmission. Remove lower cover from converter housing. Using Wrench (49-0877-435), remove torque converter-to-flexplate bolts.
4. Support transmission from below using transmission jack. Remove transmission-to-engine bolts. Slowly lower transmission assembly out of vehicle.

Installation

1. To install transmission, reverse removal procedure. Use NEW bolts and nuts for power plant frame installation. Place a straightedge on flat area in left front edge of rear crossmember. Ensure straightedge passes under power plant frame bolts. Measure from top of straightedge to power plant frame. Distance should be 2.76-3.03″ (70-77 mm). If distance is not as specified, adjust power plant frame installation.
2. Torque converter is correctly seated when distance between engine mating surface of converter housing and face of converter is at least 1.16″ (30 mm). Tighten bolts to specification. Fill transmission with required amount of fluid, and check for external leaks.

TORQUE SPECIFICATIONS

• Companion Flange Bolt/Nut: 37-43 (50-58) Ft. Lbs. (N.m)
• Crossmember Mounting Nut: 13-19 (18-26) Ft. Lbs. (N.m)
• Dipstick Stub Tube Mounting Bolt: 8 (11) Ft. Lbs. (N.m)
• Power Plant Frame
  • Bolt: 55-69 (75-93) Ft. Lbs. (N.m)
  • Nut: 109-130 (148-176) Ft. Lbs. (N.m)
• Starter Bolt: 28-38 (38-52) Ft. Lbs. (N.m)
• Torque Converter Bolt: 26-36 (35-49) Ft. Lbs. (N.m)
• Transmission-To-Engine Bolt: 28-38 (38-52) Ft. Lbs. (N.m)

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Honda S2000 clutch removal applies to 1999-2003 models.

SPECIAL TOOLS NEEDED

• Clutch alignment shaft 07LAF-PT00110
• Remover handle 07936-3710100
• Ring gear holder 07LAB-PV00100 or 07924-PD20003
• Driver 07749-0010000
• Attachment, 32 x 37 mm 07746-0010200

Pressure Plate and Clutch Disc Removal

1. Check the height-variation of the diaphragm spring fingers using the dial indicator. If the variation is more than the service limit, replace the pressure plate. See figure.

• Standard (New): 0.4 mm (0.016 in.) max.
• Service Limit: 0.6 mm (0.024 in.)

2. Install the special tools. See figure.
3. To prevent warping, unscrew the pressure plate mounting bolts in a crisscross pattern in several steps, then remove the pressure plate.
4. Remove the release bearing from the pressure plate.
5. Inspect the fingers of the diaphragm spring for wear at the release bearing contact area. See figure.
6. Inspect the surface of the pressure plate for wear, cracks, and burning.
7. Inspect for warpage using a straight edge and feeler gauge. Measure across the pressure plate. If the warpage is more than the service limit, replace the pressure plate. See figure.

• Standard (New): 0.03 mm (0.001 in.) max.
• Service Limit: 0.15 mm (0.006 in.)

8. Remove the clutch disc and special tools. See figure.
9. Inspect the lining of the clutch disc for signs of slippage or oil. If the clutch disc looks burnt or is soaked with oil, replace it. Find the source of the oil leak if the clutch disc is soaked.
10. Measure the clutch disc thickness. If the thickness is less than the service limit, replace the clutch disc. See figure.

• Standard (New): 8.2-8.9 mm (0.32-0.35 in.)
• Service Limit: 6.0 mm (0.24 in.)

11. Measure the rivet depth from the clutch disc lining surface to the rivets, on both sides. If the rivet depth is less than the service limit, replace the clutch disc. See figure 1 of 2. See figure 2 of 2.

• Standard (New): 1.2-1.7 mm (0.047-0.067 in.)
• Service Limit: 0.2 mm (0.008 in.)

Flywheel Inspection

1. Inspect the ring gear teeth for wear and damage.
2. Inspect the clutch disc mating surface on the flywheel for wear, cracks, and burning.
3. Measure the flywheel runout using a dial indicator through at least two full turns with the engine installed. Push against the flywheel each time you turn it to take up the crankshaft thrust washer clearance. If the runout is more than the service limit, replace the flywheel, and recheck the runout. Resurfacing the flywheel is not recommended. See figure.

• Standard (New): 0.05 mm (0.002 in.) max.
• Service Limit: 0.15 mm (0.24 in.)

4. Turn the inner race of the ball bearing with your finger. The ball bearing should turn smoothly and quietly. Check that the ball bearing outer race fits tightly in the flywheel. If the race does not turn smoothly, quietly, or fit tight in the flywheel, replace the ball bearing. See figure.

Flywheel Replacement

1. Install the special tool. See figure.
2. Remove the flywheel mounting bolts in a crisscross pattern in several steps, then remove the flywheel.
3. Remove the ball bearing from the flywheel. See figure.
4. Drive the new ball bearing into the flywheel using the special tools as shown. Apply a light coat of oil to the bearing surface. See figure.
5. Align the hole in the flywheel with the crankshaft dowel pin, and install the flywheel. Install the washer and mounting bolts, finger-tight.
6. Install the special tool, then torque the flywheel mounting bolts in a crisscross pattern in several steps. See figure.

Release Bearing Inspection

Check the play of the release bearing by spinning it with your hand, if there is excessive play, replace the release bearing with a new one. See figure.

The release bearing is packed with grease. Do not wash it in solvent.

Clutch Disc and Pressure Plate Installation

1. Apply a thin, uniform coat of super high temp urea grease (PN 08798-9002) to the splines of the clutch disc. Slide the clutch disc onto the mainshaft, and remove extra overflow grease.
2. Install the ring gear holder. See figure.
3. Install the clutch disc using the special tools.
4. Apply super high temp urea grease (PN 08798-9002) into the groove of the release bearing, then install the release bearing on the pressure plate. See figure.
5. Install the pressure plate and the mounting bolts, finger-tight. Make sure the release bearing does not come off.
6. Torque the mounting bolts in a crisscross pattern. Tighten the bolts in several steps to prevent warping the diaphragm spring. See figure.
   • PRESSURE PLATE MOUNTING BOLT TORQUE: 25 N.m (2.6 kgf.m, 19 lbf.ft)
7. Remove the special tools.
8. Make sure the diaphragm spring fingers are all the same height.

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1. Remove the banjo bolt and washers, then disconnect the clutch hose from the slave cylinder. Plug the end of the clutch hose with a shop towel to prevent brake fluid from coming out.

Honda S2000 1999-2003 Model

Honda S2000 2004 Model

2. Remove the two bolts and slave cylinder.
3. Pull back the boot, and apply brake assembly lube or equivalent rubber grease to the boot and slave cylinder rod. Reinstall the boot. See figure.
4. Apply super high temp urea grease (PN 08798-9002) to the tip of the slave cylinder rod.
5. Install the slave cylinder in the reverse order of removal. Use new banjo bolt washers. Make sure the boot is installed on the slave cylinder.
6. Bleed the clutch hydraulic system.

• Attach a hose to the bleeder screw, and suspend the hose in a container of brake fluid.
• Make sure there is an adequate supply of fluid at the clutch master cylinder, then slowly pump the clutch pedal until no more bubbles appear at the bleeder hose.
• Tighten the bleeder screw to 9.8 N.m (1.0 kgf.m, 7.2 lbf.ft); do not overtighten it.
• Refill the clutch master cylinder with fluid when done.
• Use only Honda DOT 3 brake fluid from an unopened container.
• Confirm clutch operation, and check for leaking fluid.

7. Make sure the fluid level in the reservoir is at the MAX (upper) level line. See figure.

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Honda S2000 Clutch Master Cylinder Removal applies to 1999-2003 models.

Do not spill brake fluid on your Honda S2000; it may damage the paint; if brake fluid does contact the paint, wash it off immediately with water.

1. The brake fluid may be sucked out through the top of the master cylinder reservo with a syringe.
2. Disconnect the clutch line from the clutch master cylinder. Plug the end of the clutch line and reservoir hose with a shop towel to prevent brake fluid from coming out.
3. Pry out the lock pin, and pull the pedal p out of the yoke. Remove the master cylinder mounting nuts.
   
4. Remove the clutch master cylinder.
   
5. Install the clutch master cylinder in the reverse order of removal. Tighten the master cylinder mounting nuts to 13 N.m (1.3 kgf.m, 9.4 lbf.ft).
6. Bleed the clutch hydraulic system
7. Refill the brake fluid in the reservoir at the MAX (upper) level line.

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The delay orifice mechanism improves clutch operation by delaying the slave cylinder release speed when the clutch pedal is suddenly released. The delay orifice mechanism is built into the slave cylinder.

When the clutch pedal is pressed, the fluid pressure from the master cylinder moves the one-way valve in the direction shown in the illustration. The fluid flows through two passages: the orifice part and the filter part. It then flows out to the slave cylinder to release the pressure plate and clutch disc joint.

When the clutch pedal is released, the fluid pressure from the slave cylinder moves the one-way valve in the direction shown in the illustration. The one-way valve blocks the filter-part passage and delays the clutch release speed by returning the fluid to the master cylinder through only the orifice-part passage.

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Clutch pedal adjustment applies to Honda S2000 1999-2003 models.

• Check the clutch pedal position switch.
• Check the clutch interlock switch.
• The clutch is self-adjusting to compensate for wear.
• If there is no clearance between the master cylinder piston and pushrod. The release bearing will be held against the diaphragm spring, which can result in clutch slippage or other clutch problems.

1. Loosen the locknut, and back off the clutch switch until it no longer touches the clutch pedal.
2. Loosen the locknut, and turn the pushrod in or out to get the specified height and stroke at the clutch pedal.

• Clutch Pedal Stroke: 115-125 mm (4.53-4.92 in.)
• Clutch Pedal Height: 189 mm (7.44 in.)

3. Tighten the locknut .
4. With the clutch pedal released, turn in the clutch pedal position switch until it contacts the clutch pedal.
5. Turn in the clutch pedal position switc an additional 3/4 to 1 turn.
6. Tighten the locknut.
7. Loosen the locknut and the clutch interlock switch.
8. Press the clutch pedal to the floor.
9. Release the clutch pedal 15-20 mm (0.59-0.79 in.) from the fully pressed position, and hold it there. Adjust the position of the clutch interlock switch so the engine will start with the clutch pedal in this position.
10. Tighten the locknut.

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Honda S2000 F20C VTEC solenoid applies to 1999-2003 AP1 models.

1. Disconnect the 1P connector from the VTEC solenoid valve.
2. Measure resistance between the terminal and body ground.
   • Resistance: 14-30 ohm



3. If the resistance is within specifications, remove the VTEC solenoid valve assembly from the cylinder head, and check the VTEC solenoid valve filter for clogging. If there is clogging, replace the engine oil filter, VTEC solenoid valve filter, and the engine oil.
   
4. If the filter is not clogged, push the VTEC solenoid valve with your finger and check its movement. If the VTEC solenoid valve is normal, check the engine oil pressure.
   

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Honda S2000 trunk components and testing applies to 1999-2003 models.

Trunk Wiring Diagram

SWITCH TEST

1. Remove the rear console.
2. Disconnect the 2P connector from the switch.
3. Check for continuity between the No. 1 and No. 2 terminals.

• There should be continuity when the switch is pushed.
• There should be no continuity when the switch is released.

4. If the continuity check is not as specified, replace the switch.

SOLENOID TEST

1. Open the trunk lid.
2. Disconnect the 3P connector from the trunk latch.
3. Check solenoid operation by connecting power and ground according to the table. To prevent damage to the solenoid, apply battery voltage only momentarily.
   
4. If the solenoid does not operate as specified, replace it.

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ROCKER ARM TEST

Special Tools Required

• Gauge joint adapter 07LAK-PR3A101
• VTEC air adapter (2) 07ZAJ-PNAA100
• Air joint adapter 07ZAJ-PNAA3000
• Air pressure regulator 07AAJ-PNAA100

1. Remove the cylinder head valve cover.
2. Set the No. 1 piston at top dead center (TDC) (see step 2 on Valve Clearance Adjustment).
3. Move the secondary rocker arm for No. 1 cylinder. The secondary rocker arm should move independently of the mid rocker arm.

• If the secondary rocker arm does not move, remove the mid, primary, and secondary rocker arms as an assembly, and check that the pistons in the mid and primary rocker arms move smoothly.
• If any rocker arm needs replacing, replace the mid, primary, and secondary rocker arms as an assembly.

4. Check that the air pressure on the shop air compressor gauge indicator is over 400 kPa (4 kgf/cm2 , 57 psi). Make sure no water in the air hose and air compressor tank.
5. Inspect the valve clearance (see Valve Clearance Adjustment).
6. Remove the No. 3 and No. 4 camshaft holder bolts, and install the VTEC air adapters finger-tight.

7. Install the gauge joint adapter to the inspection hole.
8. Connect the air joint adapter to the VTEC air adapters.
9. Connect the air pressure regulator to the air joint adapter.
10. With the specified air pressure applied and the piston at TDC, move the secondary rocker arm. The mid rocker arm, primary rocker arm, and secondary rocker arm should move together. If the three rocker arms do not move together, replace the rocker arms as a set.

11. Remove the special tools.
12. Tighten the camshaft holder bolts to 22 N.m (2.2 kgf.m, 16 lbf.ft).
13. Install the cylinder head cover.

ROCKER ARM AND SHAFT INSPECTION

1. Remove the dipstick, positive crankcase ventilation (PCV) hose and breather hose (see step 18 on Cylinder Head Removal ).
2. Remove the ignition coil cover, then remove the ignition coils (see step 19 on Cylinder Head Removal ).
3. Remove the cylinder head cover (see step 22 on Cylinder Head Removal ).
4. Loosen the rocker arm adjusting screws (see step 28 on Cylinder Head Removal ).
5. Remove the camshaft holders and camshafts.
6. Insert the bolts into the rocker shaft holder, then remove the rocker arm assembly (see step 30 on Cylinder Head Removal ).
7. Measure the diameter of the shaft at the first rocker location.

8. Zero the gauge to the shaft diameter.

9. Measure the inside diameter of the rocker arm, and check it for an out-of-round condition.

• Rocker Arm-to-Shaft Clearance:
  • Standard (New): 0.021-0.041 mm (0.0008-0.0016 in.)
  • Service Limit: 0.07 mm (0.003 in.)

10. Repeat for all rocker arms and both shafts. If the clearance is over the limit, replace the rocker shaft and all overtolerance rocker arms. If any rocker arm needs replacement, replace all three rocker arms in that set (primary, mid, and secondary).
11. Inspect the rocker arm pistons. Push each piston manually. If it does not move smoothly, replace the rocker arm assembly.

• When reassembling the primary rocker arm, carefully apply air pressure to its oil passage
• Apply new engine oil to the pistons when reassembling

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