Electronic Power Steering (Eps): Removal & Installation Mazda RX-8 I

STEERING WHEEL & COLUMN REMOVAL/INSTALLATION

Note. When replacing the steering lock of vehicles with the immobilizer system, perform the following procedure: (See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND CLEARING .)

Scheme 52

Scheme 53

1. Remove the air cleaner and air cleaner insulator. (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000) .)
2. Remove in the order indicated in the figure.
3. Install in the reverse order of removal.
4. After installation, set the EPS system to the neutral position. (See «EPS SYSTEM NEUTRAL POSITION SETTING»(ref-178305-S00086098602005061400000) .)

Steering Wheel Removal Note

1. Set the wheels in the straight-ahead position.
2. Remove the steering wheel using any commercially available puller.

Scheme 54

1. Place alignment marks on the intermediate shaft joint, and the steering gear and linkage for proper installation.
2. Loosen the joint upper bolt.
3. Remove the joint lower bolt and detach the intermediate shaft from the steering gear.

Scheme 55

1. Make a groove in the heads of the steering lock mounting bolts using a chisel and hammer.
2. Remove the bolts using a flathead screwdriver.
3. Remove the steering lock.

Scheme 56

1. Assemble the steering lock to the steering shaft.
2. Verify the operation condition of the steering lock system.
3. Install new steering lock mounting bolts.
4. Tighten the bolts until the heads break off.

Scheme 57

1. Verify that the tilt lever is in the LOCK position.
2. Temporarily tighten nuts A and B as shown in the figure.
3. Tighten the nuts to the specified torque in the order of A, B. Tightening torque 15.7-22.5 N.m {1.60-2.29 kgf.m, 11.6-16.5 ft.lbf}

Scheme 58

1. Align the marks made during removal and install the steering shaft to the steering gear.
2. Tighten the joint bolts (lower and upper). Tightening torque 17.6-26.5 N.m {1.80-2.70 kgf.m, 13.0-19.5 ft.lbf}
3. After tightening the bolts, move the intermediate shaft joint up and down and verify that it is securely installed.

Steering Wheel Installation Note

1. Set the wheels in the straight-ahead position, and install the steering wheel.

Scheme 59

Scheme 60

1. Inspect the column bearing for excessive play and damage.
2. Verify that the measurement of the steering shaft is as specified in the figure. If not within the specification, replace the steering shaft component. Standard 508.5 mm {20.02 in}
3. Inspect the tilt function operation for the following. Verify that the tilt lever moves smoothly from the lock to the unlock position. Verify that the steering shaft is fixed firmly when the tilt lever is locked. If there is any malfunction, replace the steering shaft.

STEERING GEAR & LINKAGE REMOVAL/INSTALLATION

Scheme 61

1. Remove the under cover.
2. Remove in the order indicated in (Scheme 61).
3. Install in the reverse order of removal.
4. After installation, inspect the front wheel alignment and adjust it if necessary. (See «WHEEL ALIGNMENT»(ref-178181).)
5. Set the EPS system to the neutral position. (See «EPS SYSTEM NEUTRAL POSITION SETTING»(ref-178305-S00086098602005061400000).)

Scheme 62

1. Remove the outer ball joint locknut.
2. Detach the outer ball joint from the steering knuckle using the SST.

Scheme 63

1. Temporarily tighten the bolts.
2. Tighten the steering gear and linkage installation bolts to the specified torque in the order shown in the figure. Tightening torque 74.4-104.8 N.m {7.59-10.68 kgf.m, 54.88-77.29 ft.lbf}
3. After connecting the connector, fix the wiring harness with the bands as shown in the figure.

Tie-Rod End Inspection

1. Inspect the tie-rod end for damage and excessive play. If there are any cracks, replace the tie-rod end.
2. Inspect the boot for cracks. If there is any malfunction, replace the tie-rod end boot.
3. Rotate the ball joint 5 times.
4. Measure the rotational torque of the tie-rod end using the SST and a pull scale. If not within the specification, replace the tie-rod end.

Standard rotational torque

0.6-2.0 N.m {6-20 kgf.cm, 5-17 in.lbf}

Pull scale reading

5.9-19.6 N {0.61-1.99 kgf, 1.33-4.40 lbf}

Scheme 64

EPS CONTROL MODULE REMOVAL/INSTALLATION

Scheme 65

Scheme 66

1. Remove the engine cover, battery cover, and PCM cover.
2. Remove the PCM.
3. Remove in the order indicated in (Scheme 65).
4. Install in the reverse order of removal.
5. After installation, set the EPS system to the neutral position. (See «EPS SYSTEM NEUTRAL POSITION SETTING»(ref-178305-S00086098602005061400000).)