Electronic Power Steering (Eps): Overhaul Mazda RX-8 I рестайлинг

STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

Scheme 23

Tie-rod End Disassembly Note

1. Place alignment marks as shown in the figure below for proper installation.
2. Remove the tie-rod end.

Scheme 24

Tie Rod Disassembly Note

1. Lock the steering rack end (pinion gear side) against rotation with a wrench.
2. Using the SST, remove the tie rod.

Scheme 25

Mounting Rubber Disassembly Note

1. Press the mounting rubber out from the gear housing using the SSTs and a press.

Scheme 26

Scheme 27

1. Apply soapy water to the rubber part of the mounting rubber.
2. Press the mounting rubber until the mounting rubber end comes out completely from the gear housing using the SSTs and a press.
3. Reverse the gear housing, then press the mounting rubber until the mounting rubber end comes out completely from the other side. At this time, verify that the mounting rubber and steel pipe are aligned.

Scheme 28

Tie Rod Assembly Note

1. Lock the steering rack end (pinion gear side) against rotation with a wrench.
2. Using the SST , tighten the tie rod.

Tightening torque 68.6-78.4 N.m {7.0-7.9 kg.m, 50.7-57.1 ft.lb}

Scheme 29

1. Crimp the boot band using the SST.
2. Verify that the crimping clearance A is within the specification. If crimping clearance A exceeds the specification, reduce SST clearance, and crimp the boot band again. If crimping clearance A is less than the specification, increase SST clearance, and crimp a new boot band. Standard clearance A 2-3 mm {0.08-0.11 in}
3. Rotate the boot by hand and verify that it is securely installed to the boot band.

Scheme 30

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. Tie-rod end rotation torque 0.6-2.0 N.m {6-20 kg.cm, 5-17 in.lb} Pull scale reading: 5.9-19.6 N {0.61-1.99 kg, 1.33-4.40 lb}

Scheme 31

1. Inspect for damage, bending and excessive play. If there is any malfunction, replace the steering gear and linkage.
2. Swing the ball joint 5 times .
3. Measure the swing torque using a pull scale. If it exceeds the specification, replace the steering gear and linkage. Tie-rod end swing torque 0.68-2.45 N.m {7.0-24.9 kg.cm, 6.1-21.6 in.lb} Pull scale reading: 6.8-24.5 N {0.70-2.49 kg, 1.53-5.50 lb}

Scheme 32

Scheme 33

Scheme 34

Scheme 35

1. Remove the locknut using the SST .
2. Apply sealant to the threads of the adjustment cover.
3. Tighten the adjustment cover to 20-29 N.m {2.1-2.9 kg.cm, 15-21 in.lb} .
4. After swinging the steering rack left and right 10 times , tighten the adjustment cover again to 5.8 N.m {59 kg.cm, 51 in.lb} .
5. Loosen the adjustment cover 10-20° .
6. Lock the adjustment cover against rotation and tighten the locknut using the SST . Tightening torque 20-29 N.m {2.1-2.9 kg.cm, 15-21 in.lb}
7. Measure the pinion shaft rotational torque using the SST and a pull scale. If not within the specification, repeat from Steps 1-6. Pinion shaft rotation torque 1.2-2.0 N.m {13-20 kg.cm, 11-17 in.lb} Pull scale reading: 11.2-20.0 N {1.15-2.03 kg, 2.52-4.48 lb}

Scheme 36

1. Measure the resistance between torque sensor connector terminals A and B, and B and C. If there is any malfunction, replace the steering gear and linkage. Standard A-B: 12-15 ohms B-C: 12-15 ohms