Mazda RX-8 Workshop Notebook

Workshop notes for a Series 1 Mazda RX-8: specifications, procedures, engine data and the factory oil metering pump.

• Applies to Series 1 RX-8 (2003-2008), from a 2005 UK right-hand-drive 231 PS six-port manual car. Mazda figures are from the 2003 European workshop manual.

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Specifications and reference

• Quick reference: capacities, fluids and common service values.
• Torque specifications: fastener torques by system.
• PCM terminals, relays and fault codes: the terminals and codes used in these notes.

Engine

• Engine running data: how I log a running 13B-MSP, and what the oil metering pump’s commanded step read.
• Engine removal: the ordered checklist for lifting the engine out and stripping it.
• Engine rebuild: inspection, clearances, packing the rotors, reassembly, first start.
• Rotary compression testing: test procedure, readings and my own tester design.

Cooling

• Cooling system: hose routing, draining, refilling and bleeding, and fan logic.
• Manual fan switch wiring: adding a dash switch for the cooling fans.

Lubrication and the oil metering pump

• Series 1 OMP guide: how the factory pump works, P1686 to P1688 diagnostics, servicing, nozzles and premix.
• Sohn adapter and separate oil supply: my own build for feeding the pump from a separate reservoir.
• OMP Lab: an interactive model of the pump’s start-up checks and commanded step.

Fuel, ignition and starting

• Fuel, ignition and starting: spark plugs, coils, injectors, fuel pressure and the starter.
• KEMSO fuel pump installation: fitting the uprated pump into the factory module, with Mazda’s rules for opening it and a printed retaining clip.

Drivetrain and chassis

• Drivetrain: gearbox, Power Plant Frame and differential.
• Chassis: jacking points, wheels, brakes and alignment.
• Acceleration Lab: an interactive model of gearing, road speed and full-throttle acceleration.