Mazda Car 2002-04

Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Cotter pins and nuts from both steering tie rod ends
     

  4.  
  5. Press the tie rod out from the knuckle arm.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly

  6.  
  7. Remove or disconnect the following:

    Pressure line and return pipe from the steering gear
     
    Set plate from the firewall
     
    Steering shaft to steering gear pinion shaft bolt
     
    Shaft from the steering gear
     
    Shifter linkage, if necessary
     
    Steering gear mounting nuts
     
    Steering gear from the right of the vehicle
     

  8.  

To install:

  1. Install or connect the following:

    Steering gear to the vehicle. Torque the nuts/bolts to 28-38 ft. lbs. (37-52 Nm)
     
    Steering shaft to the steering gear pinion shaft
     
    Shift linkage, if disconnected
     
    Set plate to the firewall
     
    Pressure line and return hose to the steering gear
     
    Tie rod ends to the knuckle arm. Torque the nuts to 31-42 ft. lbs. (42-57Nm)
     
    New cotter pins and check the power steering fluid level
     
    Wheels
     
    Negative battery cable
     

  2.  
  3. Check and/or adjust the front end alignment.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Cotter pins and nuts from both steering tie rod ends
     

  4.  
  5. Press the tie rod out from the knuckle arm.

    Intermediate shaft to steering gear pinion shaft bolt. Mark the shaft-to-gear location.
     
    Shaft from the steering gear
     
    Pressure and return lines
     
    Steering gear mounting nuts
     
    Steering gear and linkage from the vehicle
     

  6.  

To install:

  1. Install or connect the following:

    Steering gear and linkage to the vehicle. Torque the bolts in sequence to 55-77 ft. lbs. (75-104 Nm).
     
    Steering shaft to the steering gear pinion shaft, align the marks made during removal and tighten the bolt to 19 ft. lbs. (26 Nm)
     
    Pressure and return lines. Tighten the pressure line fitting to 34 ft. lbs. (47 Nm).
     
    Tie rod ends to the knuckle arm. Torque the nuts to 32-41 ft. lbs. (43-56 Nm).
     
    New cotter pins
     
    Wheels
     
    Negative battery cable
     

  2.  
  3. Check and/or adjust the front end alignment.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Cotter pins and nuts from both steering tie rod ends
     

  4.  
  5. Press the tie rod out from the knuckle arm.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly-626

  6.  
  7. Remove or disconnect the following:

    Transverse member
     
    Front exhaust pipe on 2.5L (KL) engines
     

  8.  
  9. Support the engine assembly with a engine support assembly such as 49 E017 5A0.

    Number 1 engine mount
     
    Pressure line and return pipe from the steering gear
     
    Intermediate shaft to steering gear pinion shaft bolt. Mark the shaft-to-gear location.
     
    Shaft from the steering gear
     
    Steering gear mounting nuts
     
    Steering gear from the right of the vehicle
     

  10.  

To install:

  1. Install or connect the following:

    Steering gear to the vehicle. Torque the nuts/bolts in sequence to 28-38 ft. lbs. (37-52 Nm).

    Click image to see an enlarged view

    Fig. Tighten the power steering gear assembly bracket retainers in this sequence-626

     
    Steering shaft to the steering gear pinion shaft, align the marks made during removal and tighten the bolt to 19 ft. lbs. (26 Nm)
     
    Pressure line and return hose to the steering gear
     
    Number 1 engine mount and remove the engine support
     
    Front exhaust pipe on 2.5L (KL) engines
     
    Transverse member
     
    Tie rod ends to the knuckle arm. Torque the nuts to 24-32 ft. lbs. (32-44 Nm).
     
    New cotter pins and check the power steering fluid level
     
    Wheels
     
    Negative battery cable
     

  2.  
  3. Check and/or adjust the front end alignment.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Intermediate shaft to steering gear pinion shaft bolt. Mark the shaft-to-gear location.
     
    Cotter pins and nuts from both steering tie rod ends
     

  4.  
  5. Press the tie rod out from the knuckle arm.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly-Protégé



    Transverse member, if necessary on some models to facilitate removal
     

  6.  
  7. Support the engine assembly with a suitable engine support assembly.

    Engine mount member
     
    Pressure line, return pipe and clamp from the steering gear
     
    Oil pipe
     
    Shaft from the steering gear
     
    Steering gear mounting nuts
     
    Steering gear from the right of the vehicle
     

  8.  

To install:

  1. Install or connect the following:

    Steering gear to the vehicle. Torque the nuts/bolts 55-77 ft. lbs. (75-104 Nm).
     
    Steering shaft to the steering gear pinion shaft, align the marks made during removal
     
    Oil pipe
     
    Pressure line, return pipe and clamp to the steering gear
     
    Engine mount member and remove the engine support
     
    Transverse member, if removed and tighten the bolts to 68-97 ft. lbs. (94-131 Nm)
     
    Tie rod ends to the knuckle arm. Torque the nuts to 24-32 ft. lbs. (32-44 Nm).
     
    New cotter pins
     
    Tighten the intermediate shaft bolt to 19 ft. lbs. (26 Nm). Check the power steering fluid level.
     
    Wheels
     
    Negative battery cable
     

  2.  
  3. Check and/or adjust the front end alignment.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Cotter pins and nuts from both steering tie rod ends
     

  4.  
  5. Press the tie rod out from the knuckle arm.
  6.  
  7. Remove or disconnect the following:

    Transverse member
     
    Pressure line and return pipe from the steering gear
     
    Intermediate shaft to steering gear pinion shaft bolt. Mark the shaft-to-gear location.
     

  8.  
  9. Support the engine assembly with a engine support assembly such as 49 E017 5A0.

    Engine mount member
     
    Number 1 engine mount bolts
     
    Upper lateral link bolt and nut
     
    Lower arm bolt on the crossmember side
     
    Stabilizer bar link
     
    Crossmember. Support with a jack before removing the bolts and nuts.
     
    Shaft from the steering gear
     
    Steering gear mounting nuts
     
    Steering gear
     

  10.  

To install:

  1. Install or connect the following:

    Steering gear to the vehicle. Torque the nuts/bolts in sequence to 23-52 ft. lbs. (44-70 Nm).

    Click image to see an enlarged view

    Fig. Tighten the power steering gear assembly bracket retainers in this sequence-Millenia

     
    Steering shaft to the steering gear pinion shaft, align the marks made during removal and hand tighten the bolt

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly-Millenia

     
    Crossmember. Support with a jack before and tighten bolts and nuts to the specifications listed in the illustration.
     
    Stabilizer bar link
     
    Lower arm bolt on the crossmember side
     
    Upper lateral link bolt and nut
     
    Number 1 engine mount bolts
     
    Engine mount member
     

  2.  
  3. Remove the engine support assembly.

    Align the marks made during removal of the steering shaft to the steering gear pinion shaft bolt and tighten the bolt to 19 ft. lbs. (26 Nm)
     
    Pressure line and return pipe to the steering gear
     
    Transverse member
     
    Tie rods to the knuckle arm. Install the nuts and tighten to 59 ft. lbs. (80 Nm) and install new cotter pins.
     
    Front wheels
     
    Negative battery cable
     

  4.  
  5. Check and/or adjust the front end alignment.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Front wheels
     
    Intermediate shaft to steering gear pinion shaft bolt. Mark the shaft-to-gear location.
     
    Cotter pins and nuts from both steering tie rod ends and press the tie rod out from the knuckle arm
     
    Stabilizer bar link
     
    Lower arm ball joint from the knuckle
     
    Pressure line and return pipe from the steering gear
     
    Bolt and power steering angle sensor connector. Remove the coolant over flow tank and set aside with the lines still attached to access the sensor connector. Refer to the exploded view illustration for component location.
     

  4.  
  5. Support the engine assembly with a engine support assembly such as 49 E017 5A0.

    Crossmember bolts. Support with a jack before removing the bolts and nuts.
     
    Front crossmember, stabilizer, lower arm and steering gear as an assembly
     

  6.  
  7. Remove the stabilizer bar, the steering gear, insulator and linkage retaining bolts and remove from the crossmember.
  8.  

To install:

  1. Attach the steering gear and insulator to the crossmember and tighten the insulator bolts to 69-95 inch lbs. (8-10 Nm) and the steering gear bolts to 55-79 ft. lbs. (74-105 Nm).
  2.  
  3. Install the stabilizer bar to the crossmember and tighten the bolts to 30-40 ft. lbs. (40-55 Nm).
  4.  
  5. Install the lower arm to the crossmember, tighten the side mounting bolt to 96-110 ft. lbs. (130-150 Nm) and the inner arm bolt to 72-97 ft. lbs. (97-132 Nm).
  6.  
  7. Install the front crossmember, stabilizer, lower arm and steering gear as an assembly, using a transmission jack to raise the assembly into position. Refer to the exploded view illustration for the crossmember bolt locations and torque values.
  8.  
  9. Install the power steering angle sensor connector, the bolt and the coolant reservoir.
  10.  
  11. Install the power steering return hose and pressure pipe. Tighten the pipe retainer to 21-32 ft. lbs. (29-44 Nm).
  12.  
  13. Install the stabilizer shaft link nut upper link, and the tie rod end ball joint. Tighten the stabilizer bar link upper nut to 30-40 ft. lbs. (40-54 Nm) and the ball joint nut to 27-37 ft. lbs. (37-50 Nm).
  14.  
  15. Install the steering shaft to the steering gear pinion shaft, align the marks made during removal and tighten the bolt to 14-18 ft. lbs. (19-25.5 Nm).
  16.  
  17. Remove the engine support assembly.
  18.  
  19. Install the front wheels and connect the negative battery cable.
  20.  
  21. Check and/or adjust the front end alignment.

    Click image to see an enlarged view

    Fig. Exploded view of the steering gear/front crossmember assembly and related components-Mazda 3

  22.  

2.3L (L3) Engine



Refer to the exploded view illustration for component location and torque specifications.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the ABS speed sensor.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the front wheels.
  8.  
  9. Remove the intermediate shaft to steering gear pinion shaft bolt. Mark the shaft-to-gear location.
  10.  
  11. Remove the cotter pins and nuts from both steering tie rod ends
  12.  
  13. Press the tie rod out from the knuckle arm.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly-Mazda 6 with the 2.3L (L3) engine

  14.  
  15. Disconnect the pressure line and return hose from the steering gear.
    CAUTION
    Do not remove the crossmember nuts completely as this may cause the crossmember to fall. Leave the nuts threaded on the studs while loosening.

  16.  
  17. Support the crossmember with a jack.
  18.  
  19. Loosen the crossmember nuts but do not remove, lower the jack and crossmember assembly enough to access to steering gear retainers.
  20.  
  21. Remove the steering gear and linkage from the left side.
  22.  

To install:

  1. Install the steering gear and linkage.
  2.  
  3. Tighten the gear mounting bolts in the sequence illustrated to 55-77 ft. lbs. (74-104 Nm).
  4.  
  5. Raise the crossmember assembly into position and tighten the nuts to 89-114 ft. lbs. (119-154 Nm) and the bolts to 68-86 ft. lbs. (93-116 Nm).
  6.  
  7. Install the return hose and pressure pipe. Tighten the pipe banjo bolt to 21-32 ft. lbs. (29-44 Nm).
  8.  
  9. Install the tie rod ends to the knuckle arm. Torque the nuts to 29-39 ft. lbs. (39-53 Nm). Install new cotter pins .
  10.  
  11. Align the intermediate shaft-to-gear marks made during removal and tighten the bolt to 13-19 ft. lbs. (18-26 Nm). Check the power steering fluid level.
  12.  
  13. Install the abs sensor and the wheels.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Check and/or adjust the front end alignment.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly-Mazda 6 models

  18.  

3.0L (Aj) Engine



Refer to the exploded view illustration for component location and torque specifications.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the ABS speed sensor.
  6.  
  7. Remove the front wheels, under cover and splash shield.
  8.  
  9. Separate the stabilizer bar link at the shock absorber side.
  10.  
  11. Separate the front lower arm front and rear ball joints from the knuckle.
  12.  
  13. Remove the lower side shock absorber bolt.
  14.  
  15. Remove the intermediate shaft to steering gear pinion shaft bolt. Mark the shaft-to-gear location.
  16.  
  17. Remove the cotter pins and nuts from both steering tie rod ends
  18.  
  19. Press the tie rod out from the knuckle arm.

    Click image to see an enlarged view

    Fig. Exploded view of the power steering gear assembly-Mazda 6 with the 3.0L (AJ) engine

  20.  
  21. Remove the heat shield bolts.
  22.  
  23. Disconnect the pressure line and return hose from the steering gear.
  24.  
  25. Remove the No. 1 engine mount center bolt.
    CAUTION
    Support the crossmember with a jack and make sure the jack is attached securely to the crossmember before removing the bracket.

  26.  
  27. Support the crossmember with a jack.
  28.  
  29. Remove the crossmember bracket.
  30.  
  31. Remove the crossmember bolts and lower the crossmember assembly with the gear and linkage attached.
  32.  
  33. Remove the heat shield and return hose.
  34.  
  35. Remove the steering gear and linkage.
  36.  

To install:

  1. Install the steering gear and linkage to the crossmember assembly.
  2.  
  3. Tighten the gear mounting bolts in the sequence illustrated to 55-77 ft. lbs. (74-104 Nm).
  4.  
  5. Install the return hose and heat shield but do not tighten the shield bolts.
  6.  
  7. Raise the crossmember assembly into position and tighten the retainers to the specifications shown in the accompanying illustration.
  8.  
  9. Install the crossmember bracket and tighten the retainers to the specifications shown in the accompanying illustration.
  10.  
  11. Install the No. 1 engine mount center bolt and tighten to 68-86 ft. lbs. (93-116 Nm).
  12.  
  13. Install the return hose and pressure pipe. Tighten the pipe banjo bolt to 21-32 ft. lbs. (29-44 Nm).
  14.  
  15. Install the heat shield bolts and tighten to 79 inch lbs. (10 Nm).
  16.  
  17. Install the tie rod ends to the knuckle arm. Torque the nuts to 29-39 ft. lbs. (39-53 Nm). Install new cotter pins .
  18.  
  19. Align the intermediate shaft-to-gear marks made during removal and tighten the bolt to 13-19 ft. lbs. (18-26 Nm). Check the power steering fluid level.
  20.  
  21. Install the lower side shock absorber bolt.
  22.  
  23. Attach the front lower arm front and rear ball joints to the knuckle.
  24.  
  25. Attach the stabilizer bar link to the shock absorber side.
  26.  
  27. Install the abs sensor, wheels, splash shield and under cover.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Check and/or adjust the front end alignment.
  32.  

 
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