Mazda Car 2002-04

Removal & Installation 2

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  1. Installation is the reverse of removal, please note the following:
    1. Adjust the clock spring as follows:
      CAUTION
      If the clock spring is not adjusted, the spring wire in the clock spring could over-wind and break when the steering wheel is turned. Always adjust the clock spring after installing it.


      CAUTION
      The clock spring will break if over-wound. Do not forcibly turn the clock spring.



      Set the front tires straight-ahead
       



      Turn the clock spring clockwise until it stops

      Click image to see an enlarged view

      Fig. Turn the clock spring clockwise until it stops-Mazda 3



      Click image to see an enlarged view

      Fig. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns-Mazda 3



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      Fig. Align the marks on the clock spring-Mazda 3

       
      From the stopped position, turn the clock spring counterclockwise 2 3 / 4 turns
       
      Align the marks
       
      Verify that the tilt / telescope lever is in the LOCK position
       

    2.  
    3. Tighten the steering shaft bolts in alphabetical order.

      Click image to see an enlarged view

      Fig. Tighten the steering shaft bolts in alphabetical order-Mazda 3

    4.  
    5. Set the wheels in the straight-ahead position and install the steering wheel
      CAUTION
      When installing the center panel module, make sure that the wiring harness and antenna feeder are not caught between the unit and dashboard. If the wiring harness or the antenna feeder is caught between the unit and dashboard, it may cause malfunctions.

    6.  
    7. Select Cable for models with an manual transmission should be installed as follows:

      Make sure that the shift lever (transaxle side) is in neutral
       
      Push the safety lock, then unlock the lock piece of the select cable in the order shown in the illustration.
       
      Shift the sift lever to neutral.
       
      Lock the lock piece of the selector cable in the illustration.
       
      Shift the shift lever from neutral to other position, and make sure that there are no other components in that area to interfere with the lever.

      Click image to see an enlarged view

      Fig. Push the safety lock, then unlock the lock piece of the select cable in the order shown, on manual transmissions-Mazda 3



      Click image to see an enlarged view

      Fig. Lock the lock piece of the selector cable, on manual transmissions-Mazda 3

       

    8.  
    9. Selector lever for models with an automatic transmission should be installed as follows:

      Insert the location pin of selector lever component to the hole of the floor
       
      Tighten the selector lever component installation bolts to 7.8-10.8 Nm (69.5-95.4 in. lbs.).

      Click image to see an enlarged view

      Fig. Insert the location pin of selector lever component to the hole of the floor on models with an automatic transmission-Mazda 3



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      Fig. Verify the selector cable is in this position on models with an automatic transmission-Mazda 3



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      Fig. Lock the lock piece and safety lock of the selector cable in this order on models with an automatic transmission-Mazda 3



      Click image to see an enlarged view

      Fig. Bending the selector cable in the manner shown in the illustration will damage the cable and it may become loose when shifted on models with an automatic transmission-Mazda 3

       

    10.  
    11. Selector Cable for models with an automatic transmission should be installed as follows:
      CAUTION
      Bending the selector cable in the manner shown in the illustration will damage the cable and it may become loose when shifted. When installing the selector cable, hold it straight.


      NOTE
      Install the selector cable to the manual shaft cable with the clip side of the selector cable end facing the front of the vehicle.



      Install the selector cable to the selector lever securely.
       
      Install the selector cable to the bracket securely.
       



      Install the clip as shown in the illustration.
       



      Install the selector cable to the manual shaft lever in such a way that the selector cable does not bear a load.
       
      Confirm that the end of the manual shift lever projects from the end of the selector cable.

      Click image to see an enlarged view

      Fig. Install the selector cable to the manual shaft cable with the clip side of the selector cable end facing the front of the vehicle on models with an automatic transmission-Mazda 3



      Click image to see an enlarged view

      Fig. Install the selector cable to the manual shaft lever in such a way that the selector cable does not bear a load on models with an automatic transmission-Mazda 3

       
      Install the selector cable to the selector cable bracket securely.
       

    12.  
    13. Install the connector B as shown in the illustration.

      Click image to see an enlarged view

      Fig. Install the connector B as shown-Mazda 3



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      Fig. After connecting connector A, rotate the lever in the direction of the arrow-Mazda 3

    14.  
    15. After connecting connector A, rotate the lever in the direction of the arrow to install connector A.
    16.  
    17. Turn the ignition switch to the ON position.
    18.  
    19. Verify that the air bag system warning light goes out.
    20.  
    21. If the air bag system warning light does not operate normally, inspect of the system.
    22.  

  2.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the glove compartment.
  4.  
  5. Remove the duct.
  6.  
  7. Remove the air intake actuator connector and actuator.
  8.  

To install:

  1. Installation is the reverse of removal.
  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the battery, wait for more than 1 minute for the SAS to deplete its stored energy.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. At the driver-s side, remove the SAS module and the steering wheel by removing or disconnecting the following:

    Place the wheel in the straight-ahead position and turn the ignition switch to LOCK
     
    Cover clips at both sides of the steering wheel
     
    Steering wheel-to-SAS module clips
     
    SAS module from the steering wheel and disconnect the electrical connector
     
    Steering wheel-to-column nut
     
    Steering wheel from the steering column using a suitable puller
     

  10.  
  11. At the passenger-s side, remove the SAS module by removing or disconnecting the following:

    Glove compartment and the glove compartment cover
     
    SAS module-to-dash bolts
     
    SAS module and disconnect the electrical connector
     

  12.  
  13. Remove the rear console by removing or disconnecting the following:

    Rear console-s box
     
    Bake boot
     
    Center panel
     
    Rear console
     

  14.  
  15. Remove or disconnect the following:

    A-pillar trim at both sides
     
    Undercover at the passenger-s side
     
    Upper and lower steering column covers
     
    Electrical connectors and remove the combination switch from the steering column
     
    Meter hood
     
    Electrical connectors and remove the instrument cluster
     
    Steering column-to-chassis bolts and the steering column
     
    Hood release lever
     
    Both side panels
     
    Instrument panel with the help of an assistant
     
    Actuator connector and actuator

    Click image to see an enlarged view

    Fig. Exploded view of the SAS module and steering wheel assembly-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the passenger-s side SAS module-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and steering column assembly-Millenia



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and rear console assemblies-Millenia

     

  16.  

To install:

  1. Install or connect the following:

    Actuator and the connector
     
    Instrument panel with the help of an assistant
     
    Both side panels
     
    Hood release lever
     
    Steering column and the steering column-to-chassis bolts
     
    Instrument cluster and connect the electrical connectors
     
    Meter hood
     
    Combination switch to the steering column and connect the electrical connectors
     
    Upper and lower steering column covers
     
    Undercover at the passenger-s side
     
    A-pillar trim at both sides
     

  2.  
  3. Install the rear console by installing or connecting the following:

    Rear console
     
    Center panel
     
    Brake boot
     
    Rear console-s box
     

  4.  
  5. At the passenger-s side, install the SAS module by installing or connecting the following:

    SAS module and connect the electrical connector
     
    SAS module-to-dash bolts
     
    Glove compartment cover and the glove compartment
     

  6.  
  7. At the driver-s side, install the SAS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-column nut. Torque the nut to 29-36 ft. lbs. (40-49 Nm).
     
    SAS module to the steering wheel and connect the electrical connector. Torque the bolts to 79-113 inch lbs. (9-13 Nm).
     
    Steering wheel-to-SAS module clips
     
    Cover clips at both sides of the steering wheel
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Evacuate, charge and leak test the air conditioning system refrigerant.
  14.  
  15. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  16.  

 
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