Hey guys, buckle up because today we're diving deep into the heart of automotive engineering! I'm stoked to share my experience cracking open the legendary Mazda FD RX-7's rotary engine. Yeah, you heard that right! I meticulously documented every single step, from the very first nut and bolt removal to the final triumphant startup. So, if you're into the world of rotary engines, engine repair, or just love a good restoration story, you're in the right place. This FD RX-7 rebuild isn't just about fixing an engine; it's about passion, persistence, and the sheer joy of bringing a mechanical marvel back to life. I'll walk you through the entire process, sharing the highs, the lows, and everything in between. Get ready for a roller-coaster ride as we explore the intricacies of the rotary engine and witness the transformation of my FD RX-7.
Disassembly: The Art of Taking Things Apart
Alright, let's kick things off with the disassembly phase. This is where we methodically dismantle the engine, piece by piece. Think of it as an automotive archaeological dig, where we're unearthing the secrets of the rotary engine. Before we get our hands dirty, it's crucial to have a well-organized workspace, tons of ziplock bags, and a camera ready to capture every detail. Trust me, you'll want to take photos and notes of EVERYTHING! The last thing you want is to get lost in a maze of bolts and components when it's time to reassemble. Engine repair is always a puzzle. During the RX-7 engine rebuild, I started by draining all the fluids, including oil and coolant. Safety first, always! Then, I systematically disconnected all the hoses, wires, and sensors connected to the engine. Labeling each one as you go is a lifesaver. Trust me, the frustration of trying to figure out where a wire goes after months is not fun. Next, it was time to remove all the external components: the intake manifold, exhaust manifold, water pump, oil cooler, and everything else that was bolted onto the engine. This is where the real fun begins! You'll encounter some stubborn bolts that have been fused together by years of heat and grime. Penetrating oil is your best friend here. Let it soak in for a while and then try again. Patience is key. Once all the external components were removed, I could finally separate the engine from the transmission. This usually involves removing the bell housing bolts and carefully sliding the engine away. Now comes the moment of truth: pulling the engine out of the car. This can be done with an engine hoist. After the engine was safely out of the car, I placed it on an engine stand, which is a rotating stand, so that you can access all sides of the engine easily. Then the real disassembly begins. Taking off the front and rear housings and then the rotor housings. Taking off the rotor housings and the rotor. I also inspected the various parts, such as the rotors, housings, and seals, for wear and damage. The goal here is to identify any components that need replacing, which will determine the next phase of the RX-7 engine rebuild.
Inspection and Cleaning: Unveiling the Engine's Secrets
Now that the engine is in pieces, it's time for the inspection and cleaning phase. This is where we get to know the engine intimately. We closely examine each component for wear, damage, and any signs of failure. This is where we determine what needs to be replaced and what can be reused. First, I gave all the components a thorough cleaning. I used a combination of degreaser, brushes, and compressed air to remove all the dirt, grime, and carbon buildup. A clean engine is a happy engine, right? Then, it was time for the inspection. I started with the rotor housings, checking for any scratches, scoring, or wear on the inner surfaces. I also inspected the rotor faces and side seals. The apex seals are especially critical, as they seal the combustion chamber. If they're worn or damaged, you'll have a loss of compression and poor engine performance. For the rotor housings, I measured the dimensions to ensure they were within the factory specifications. If they were excessively worn, I would need to replace them. Next, I checked the rotors for any damage, such as cracks or pitting. I also inspected the bearings and the eccentric shaft for wear. The bearings support the rotors, so any damage here can lead to serious engine problems. The eccentric shaft is the heart of the engine, as it converts the rotary motion of the rotors into the rotational force that drives the wheels. So any damage to this would cause major engine issues. I measured the dimensions of each component using calipers and a micrometer. This is crucial for ensuring that everything is within the factory specifications. This is critical for ensuring the engine's longevity and optimal performance. Any components that were out of spec or showed significant wear were marked for replacement. This is an important step to ensure the engine's health and ensure that it performs at its best. This is where you start to make the crucial decisions that will influence the entire project. After everything was inspected and cleaned, I moved on to the next phase of the FD RX-7 engine rebuild.
Reassembly: Bringing the Rotary Back to Life
This is where we get to the exciting part: reassembly. This is where we transform a pile of parts into a fully functioning engine. This is where the magic happens. Armed with my new parts, I carefully put everything back together. This stage demands precision and attention to detail. Every bolt, every seal, every component must be installed correctly to ensure the engine runs smoothly and reliably. First, I started by installing the new apex seals, side seals, and corner seals into the rotors. These seals are critical for sealing the combustion chamber and preventing compression loss. I also installed new bearings on the eccentric shaft. Make sure to lubricate everything with plenty of oil! Next, I carefully positioned the rotors into the rotor housings. This is a delicate process, as you need to align the rotor with the eccentric shaft without damaging the seals. I then installed the rotor housings onto the engine block and torqued all the bolts to the factory specifications. This is where you need to pay close attention to the torque specs. Make sure to use a torque wrench to tighten all the bolts to the correct torque. Over-tightening or under-tightening bolts can lead to engine damage. Next, I installed the front and rear housings. Make sure to install the dowel pins correctly, as these are critical for aligning the housings. I then installed the water pump, oil cooler, intake manifold, and exhaust manifold. This is where you start to see the engine come back to life. Finally, I reconnected all the hoses, wires, and sensors. This is the final step to the FD RX-7 engine rebuild. Once everything was reassembled, I filled the engine with oil and coolant and prepared for the first start-up.
First Start and Beyond: The Moment of Truth
Alright, the moment we've all been waiting for: the first start. This is where all the hard work and dedication culminates in a single, heart-pounding moment. The anticipation is intense. Will it start? Will it run smoothly? Or will something go horribly wrong? Before turning the key, I double-checked everything: all the connections, all the fluids, and all the bolts. Then, with a deep breath, I turned the key. The engine cranked, and then... it sputtered to life! There was a moment of relief, followed by a surge of adrenaline. The engine was alive! I let it run for a while, monitoring the oil pressure, temperature, and any unusual noises. Luckily, everything seemed to be working as it should. After the first start, I began the break-in period. This is a crucial period where the engine is gradually run in to allow the seals and components to seat properly. I followed a specific break-in procedure, which involved varying the engine speed and avoiding high loads. Over time, the engine's performance improved, and it started to feel stronger and more responsive. But the RX-7 engine rebuild doesn't end there. After completing the build, there is maintenance, tuning, and constant upgrades to make sure everything is running at its best. With a properly rebuilt engine, you can experience the unique character and power delivery of a rotary. This project was a test of patience, skills, and passion for cars. But the reward is worth it. There is nothing like the feeling of hearing the engine purr once again. If you're considering embarking on a similar journey, my advice is: do your research, be patient, and don't be afraid to ask for help. The rotary engine is a complex but rewarding piece of engineering. So there you have it, the complete journey of rebuilding my FD RX-7's rotary engine. From the initial disassembly to the first triumphant start-up, it was a wild ride. I hope you enjoyed following along. If you're interested in seeing more detailed videos of the process, with every nut and bolt, let me know in the comments below. Thanks for watching, and happy wrenching, guys!
