Mazda Car 2002-04

Removal & Installation

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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-Mazda6and Mazdaspeed6 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-Mazda6 and Mazdaspeed6 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-Mazda6 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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