2nd gen RX-7 / Ford 2.3 4cyl...
...Considerations & Requirements

Considerations...

Selling Your Stock Engine/Turbos/Trans...
...If your engine/turbos/transmission are in running condition, the best time to secure a buyer is while they are still in use, where the running condition can be easily verified by the prospective buyer. This way, there is no question about the compression, boost pattern, seal condition, etc. There are many more RX-7’s than there are available running engines, so a good engine can demand a premium price. This can go a long way to help defray the cost of your 2.3 conversion.

Tools Required...

...Both Metric & inch sized hand tools
...Floor Jack
...Engine Hoist
...A minimum of (4) Jack Stands
...Drain Buckets & Floor Dry
...Coolant Storage Buckets
...Penetrating Oil
...Tags (for labeling parts & wires)
...12v Test Lite / Volt-Ohm Meter
...Fender Covers
...Drop Light
...RX-7 Shop Manual
...Shop Manual for New Engine / Trans
...Small Storage Boxes (for bolts & small parts)
...Wiring Terminal End Assortment & Crimping Pliers
...Wire (misc colors for extending harnesses)
...Wire (for temporary support of misc. components)

Parts Included In Our 2nd Gen Ford 2.3 Basic Kit...

...2.3 Basic Kit instructions
...Engine Chassis Brackets "right" & "left"
...Transmission crossmember
...Engine rubber mounts- (2) NAPA #602-1108
...T5 Shifter Extension

Optional Parts Available From Granny's...
...Transmission rubber mount- (1) NAPA #620-1040
...Custom aluminum radiator and bolt-in bracket set
...Condensor core re-location brackets
...Temp sender adapter bushing
...Speedometer cable adapter
...Driveshaft w/ slip yoke

...Additional Parts Required...

Complete engine including...
......Induction system
......Emissions system
......Starter
......Merkur Engine Extensions

Complete transmission assy. including ....
...Manual trans...
......Flywheel w/ correct balance weight
......Clutch disc / pressure plate / throwout bearing
......Bellhousing / output yoke
......Shifter / knob
......Shifter extension
......Clutch release parts (see NOTE below)
...Auto trans...
......flex plate w/ correct balance weight installed
......Shifter w/ neutral safety switch
......oil cooler

Optima style dry cell battery
Battery box/hold down
Battery cable & ends
Radiator hose clamps
Heater hose & clamps
Heater hose restrictor fitting
Oil cooler adapter, hoses, & fittings
Air cleaner & Piping
Throttle cable
Engine Oil & Tune-Up Supplies
Transmission Gear Oil
Brake Fluid (for clutch hyd. system)
Preventitive Maintenance Parts (gaskets, seals, bushings, bearings, etc.)

...Recommended Work Area...

...The bare minimum should include a level, dry cement or asphalt surface to provide firm and safe support for your jack stands, as well as to ease the rolling around of the engine hoist and floor jack.

...Engine Preparations...

...To minimize the down-time required to complete the conversion, the new engine should be prepped & detailed in advance.

Removing Un-needed Parts & Accessories...
...Remove the alternator and stock motor mounts. After you’re done, now would be a good time to pressure wash the engine, before it gets “too” exposed.
...Remove the stock exhaust manifolds. Use a 6 point socket, and be careful not to break any bolts.
...Remove the distributor & intake manifold.

Preventive Maintenance...
...If there is any PM to be done on your new engine, now is the time to do it. Replace any leaking seals or gaskets. If you want to install a new timing chain, oil pump, etc, it will never be easier than now.

OPTIONAL STEP: Installing an Oil Cooler Adapter...
...use an oil cooler adapter that installs between the block and the oil filter, such as those available from Fram or Trans-Dapt (TD Products). Follow the instructions that comes in the kit for adapter installation. New hoses can be fabricated using fittings salvaged from the oil cooler end of the original RX-7 hoses.

...Transmission Preparations...

Prevenitive Maintenence...
...now would be an excellent time to change the front and rear seals, as well as the gear oil/fluid. If you are using an automatic trans, now would be a good time to change the filter and install a drain plug in the transmission pan. B&M sells one that's easy to install.

Joining The Engine / Transmission...
...it's easiest to install the engine/trans as a unit. Be sure to use the correct flywheel/flexplate bolt (too long can bottom out or hit the rear face of the block). Properly torque the flywheel/flexplate bolts as recommended in the shop manual BEFORE joining the engine/trans.
T-5 Only...NOTE: The 2.3 bellhousings typically used a pull-style cable clutch linkage with a bellcrank. When installing into a RX-7, there are a few options with regards to clutch actuation...
...OPTION #1- install a Mustang style clutch quadrant and cable system under the dash of the RX-7. Aftermarket adjustable quadrants are available from such sources as Summit Racing that make this job easier, but you are still going to be working upside down under the dash for a while.
...OPTION #2- convert to a push style hydraulic slave system using the existing RX-7 slave. This requires drilling a couple holes in the flat surface of the bellhousing just in back of the throwout fork, mounting the slave so that it can push the throwout fork from the rear.
You will also need a larger clutch master cylinder. We use a Wilwood 7/8" bore unit with a remote reservoir, necessary due to the 2nd gen RX-7's angled clutch master cylinder mounting stud bolt pattern.
We install the clevis from the RX-7 master cylinder pushrod onto the Wilwood pushrod. The threads are very close and do not require additional tapping.
...OPTION #3- install an internal "hydraulic throwout bearing" onto the front of your T-5 trans. A larger 7/8" bore clutch master cylinder is also required if you go this route.

...Pre-conversion Last Minute Preparations...

Draining / Evacuating Your AC System...
...While your RX-7 is still mobile is the best time to have your AC system properly evacuated by a professional. Not only is it illegal to release your refrigerant into the atmosphere, it is also bad to expose the inside of your AC components to the outside moisture laden air. A pro will be able to evacuate and seal your system, and at the same time he can recover and save your rare and valuable R-12 for re-use later.

Pressure Washing The Engine Compartment...
...On your way back from the AC shop, it’s a good idea to stop by the car wash and give the underhood area a good, thorough pressure washing. You would be surprised at how much easier and more enjoyable the job will be when you can actually see what you’re working on.

Next page....

1....Introduction....

2....Considerations & Requirements....

3....Getting Started....

4....Engine / Transmission Installation....

5....Exhaust / Throttle Cable / Accessory Drive / Pulleys....

6....Cooling / Fuel Systems....

7....RX-7 Wiring Harness Connector ID and Circuit Locations....

8....Electrical System Modifications By Circuit....

9....Start-up / Troubleshooting....

10....Upgrades....

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