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DocumentCreationInfo

STEERING 19 -

STEERING

TABLE OF CONTENTS

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STEERING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . 1
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

STEERING
DESCRIPTION

CAUTION: Use approved fluid only in the power steering system (Refer to LUBRICATION &
MAINTE- NANCE/FLUID TYPES - DESCRIPTION). No other power steering or automatic
transmission fluid is to be used in the system. Damage may result to the power steering pump
and system if any other fluid is used, and do not overfill.
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Power steering systems consist of:


• Steering column
• Rack and pinion steering gear
• Belt driven hydraulic steering pump
• Pump pressure and return hoses
• Oil Cooler

OPERATION
The steering column shaft is attached to the gear pinion. The rotation of the pinion moves the gear rack
from side-to-side. This lateral action of the rack pushes and pulls the tie rods to change the direction of the
front wheels (Fig. 1).
Power assist is provided by an engine mounted hydraulic pump which supplies hydraulic fluid pres- sure to
the steering gear.

Fig. 1 STEERING COMPONENTS


1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
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4 - TIE ROD ENDS


5 - MOUNTING BOLTS
6 - RACK & PINION

DIAGNOSIS AND TESTING - POWER STEERING SYSTEM


There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill parking. Or when the steering wheel is at the end of it’ s travel. Hiss is a high frequency noise similar
to that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid
passing through an orifice. There is no relation- ship between this noise and steering performance.
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STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION

OBJECTIONAL HISS OR
WHISTLE 1. Steering intermediate shaft to 1. Check and repair seal at dash
dash panel seal. panel.
2. Noisy valve in power steering 2. Replace steering gear.
gear.

RATTLE OR CLUNK
1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension 2. Inspect and repair suspension.
compo- nents.
3. Internal gear noise. 3. Replace steering gear.
4. Pressure hose in contact with 4. Reposition hose.
other components.
5. Loose or damaged 5. Inspect and repair or replace.
intermediate shaft or column.

CHIRP OR SQUEAL
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1. Loose belt. 1. Adjust or replace.

WHINE OR GROWL
1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with 2. Reposition hose.
other components.
3. Internal pump noise. 3. Replace pump.
4. Air in fluid 4. Check for lekas, Evacuate air
from P/S system.

SUCKING AIR SOUND


1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on 2. Replace o-ring.
hose fitting.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and 4. Repair as necessary.
reservoir.
5. Reservoir cap not installed 5. Install reservoir cap correctly.
correctly.

SCRUBBING OR KNOCK- ING


1. Wrong tire size. 1. Verify tire size.

BINDING AND STICKING


CONDITION POSSIBLE CAUSE CORRECTION

DIFFICULT TO TURN WH
EL 1. Low fluid level. 1. Fill to proper level.
STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball 3 Inspect and repair as
joints/ necessary.
tie rod ends).
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4. Loose belt. 4. Adjust or replace.


5. Low pump pressure. 5. Pressure test and replace if
nec- essary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
8. Pump seized / Stuck valve 8. Replace pump.
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COLUMN
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INSUFFICIENT ASST. OR POOR RETURN TO CENTER

CONDITION POSSIBLE CAUSE CORRECTION

HARD TURNING OR MOMEN-


TARY INCREASE IN TURNING 1. Tire pressure. 1. Adjust tire pressure.
EFFORT
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as
nec- essary.
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5. Replace gear.
5. Internal gear leak.

STEERING WHEEL DOES NOT


WANT TO RETURN TO 1. Tire pressure. 1. Adjust tire pressure.
CENTER POSITION 2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate
suspension compnents.
4. Replace gear.
4. High friction in steering gear.

LOOSE STEERING AND VEHICLE LEAD

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE PLAY IN
STEERING WHEEL 1. Worn or loose suspension or 1. Inspect and repair as
steering components. necessary.

2. Worn or loose wheel bearings.


2. Inspect and repair or adjust
bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Replace gear.
5. Inspect and replace as neces-
4. Gear out of adjustment. sary.
5. Worn or loose steering
coupler.

VEHICLE PULLS OR LEADS TO


ONE SIDE. 1. Tire Pressure. 1. Adjust tire pressure.
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2. Radial tire lead. 2. Rotate tires.


3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
COLUMN

TABLE OF CONTENTS

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COLUMN
SPECIFICATIONS - TORQUE CHART . . . . . . . . . 4
INTERMEDIATE SHAFT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
KEY/LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING WHEEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6

COLUMN
SPECIFICATIONS - TORQUE CHART

TORQUE SPECIFICATIONS
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DESCRIPTION N·m Ft. Lbs. In. Lbs.


Steering Wheel With Air- 80 59 —
bag To Steering Shaft
Jacket Tube For 25 18 221
Steering
Shaft To Waist Rail
U-Joint To Steering 24 18 212
Gear
Shaft
INTERMEDIATE SHAFT
REMOVAL
(1) Disconnect the ground cable from the battery. (2) Remove the air bag module from the steering
wheel.
(3) Turn the steering wheel and lock the steering wheel in the straight ahead position. The position of the
steering gear must not be altered again for the entire duration of the work procedure.
(4) Remove the electrical center.
(5) Remove the steering wheel bolt.
(6) Remove the steering wheel from the steering column.
(7) Remove the clockspring. Unscrew the retain- ing bolts just enough to be able to remove the clockspring.
Do not twist or disassemble the clockspring.
(8) Remove the combination switch.
(9) Disconnect the electrical connector for the igni- tion lock.
(10) Remove the spring for the brake pedal from the steering column.
(11) Remove the fitted bolt from the universal joint
(Fig. 1).
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Fig. 1 U-JOINT REMOVE / INSTALL


1 - FITTED BOLT
2 - U-JOINT

(12) Remove the bolts in the steering column bracket (Fig. 2).

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1 - BOLT
Fig. 2 STEERING COLUMN BOLTS
Fig. 3 TRANSPONDER
1 - TRANSPONDER
2 - COLUMN BOLT
2 - STEERING COLUMN

(13) Remove the steering shaft with the universal joint off the steering gear drive shaft (Fig. 1).
(14) Pull the steering shaft out of the rubber grom- met in the cab floor.

INSTALLATION
(1) Install the steering shaft through the rubber grommet in the cab floor. Ensure that the rubber grommet is
properly seated.
(2) Install the steering shaft with the universal joint onto the steering gear shaft (Fig. 1).
(3) Install the bolts in the steering column bracket
(Fig. 2). Tighten to 24 N·m (18 ft. lbs.).
(4) Install the universal joint on the steering gear shaft (Fig. 1). Tighten to 24 N·m (18 ft. lbs.).
(5) Install the spring for the brake pedal to the steering column.
(6) Reconnect the electrical connector to the igni- tion lock.
(7) Install the combination switch. (8) Install the clockspring.
(9) Install the steering wheel. (10) Install the electrical center.
(11) Reconnect the ground cable to the battery.

KEY / LOCK CYLINDER


REMOVAL
(1) Remove the securing cover for the central elec- tronics.
(2) Remove the steering column shroud.
(3) Remove the transponder coil off the ignition lock (Fig. 3).
(4) Insert the key into the ignition lock.
(5) Turn the ignition key to the first detent (Fig.
4).
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Fig. 4 IGNITION LOCK FIRST DETENT


1 - LOCK HOUSING

2 - FIRST DETENT WITH KEY INSTALLED

(6) Turn the cap a 1/4 turn to the left (Fig. 5).
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Fig. 5 1/4 TURN LEFT


1 - STEERING COLUMN
2 - 1/4 TURN TO THE LEFT

(7) Remove cap together with the lock cylinder off the ignition lock (Fig. 6).
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INSTALLATION
(1) Install the cap together with the lock cylinder onto the ignition lock (Fig. 6).
(2) Turn the cap a 1/4 turn to the right.
(3) Turn the ignition key to the first detent (Fig.
4).
(4) Remove the ignition key from the ignition lock. (5) Install the transponder coil onto the ignition
lock (Fig. 3).
(6) Install the steering column shroud. Pay atten- tion to the cables routed under the steering col- umn cover.
Do not trap the cables.
(7) Install the cover for the central electronics.

STEERING WHEEL
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REMOVAL
(1) Disconnect the ground cable on the battery.
(2) Remove the air bag module from the steering wheel.
(3) Turn the steering wheel and lock the steering wheel in the straight ahead position (Fig. 7).
(4) Remove the steering wheel bolt (Fig. 7).
(5) Remove the steering wheel from the steering column (Fig. 7).

Fig. 7 STEERING WHEEL


1 - STEERING WHEEL
2 - STEERING WHEEL BOLT

INSTALLATION
(1) Install the steering wheel onto the column (Fig.
7).
(2) Install the steering wheel bolt (Fig. 7). Tighten to 80 N·m (59 ft. lbs.).
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(3) Install the air bag module.


Fig. 6 LOCK CYLINDER OFF (4) Reconnect the battery ground cable.
THE IGNITION LOCK
1 - LOCK HOUSING (5) Reset all the times and encode the
radio.

2 - LOCK CYLINDER (6) Perform a road test to check the


position of the
steering wheel.

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GEAR

TABLE OF CONTENTS

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GEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS - TORQUE CHART . . . . . . . . . 8

GEAR
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DESCRIPTION
A rack and pinion steering gears (Fig. 1) is made up of two main components, the pinon shaft and the rack. The
gear cannot be adjusted or internally ser- viced. If a malfunction or a fluid leak occurs, the gear must be
replaced as an assembly.

Fig. 1 STEERING GEAR


1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS

REMOVAL
(1) Siphon the power steering fluid out of the res- ervoir.
(2) Raise and support the vehicle. (3) Remove the front wheels.
(4) Remove the stabilizer bar from the upper part of the stabilizer link (Refer to 2 - SUSPENSION/
FRONT/STABILIZER LINK - REMOVAL).
(5) Remove the outer tie rod end nuts and sepa- rate the tie rods from the steering knuckles (Fig. 2) using
special tool C-3894– A.
(6) Remove the left outer tie rod end from the steering gear.
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(7) Remove both spring clamp plates (Refer to 2 - SUSPENSION/FRONT/SPRING CLAMP PLATES -
REMOVAL).
(8) Remove both the high pressure and return hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 2).
(9) Remove the steering shaft clamping bolt from the steering gear (Fig. 2).
(10) Separate the universal joint from the steering gear (Fig. 2).
(11) Remove the steering gear bolts from the front axle.
(12) Remove the steering gear by sliding it toward the passengers side of the vehicle and then tilt down- ward
on the drivers side and remove from vehicle.

Fig. 2 STEERING GEAR REMOVAL / INSTALL


1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
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10 - U-JOINT CLAMPING BOLT

INSTALLATION
(1) Install the gear to the vehicle.

NOTE: Steering gear must be torqued in a three step procedure below.

(2) Install the steering gear bolts (Fig. 2). Tighten to an initial torque of 25 N·m (18 ft. lbs.) Then

19 - 8 GEAR
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torque to 45 N·m (33 ft. lbs.) and a final additional


90° turn for final torque.
(3) Install the universal joint to the steering gear
(Fig. 2). Tighten to 24 N·m (18 ft. lbs.).
(4) Install both the power steering hoses to the steering gear (Fig. 2). Tighten the high pressure hose to 37
N·m (27 ft. lbs.).
(5) Install the spring clamp plates (Refer to 2 - SUSPENSION/FRONT/SPRING CLAMP PLATES -
INSTALLATION).
(6) Install the left outer tie rod end to the steering gear.
(7) Install both the outer tie rod ends to the steer- ing knuckle (Fig. 2). Tighten to 130 N·m (96 ft. lbs.). (8)
Install the upper stabilizer bar link to the sta-
bilizer bar.
(9) Install the front wheels.
(10) Fill and bleed the power steering system (Refer to 19 - STEERING/PUMP/FLUID - STAN-
DARD PROCEDURE).
(11) Reset toe adjustment.
(12) Check steering system for leaks.

SPECIFICATIONS - TORQUE CHART


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TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


U-Joint To Steering 24 18 212
Gear
High Pressure Hose To 37 27 328
Steering Gear
Return Line To Steering 37 27 328
Gear
Steering Gear To Frame 25 18 221
Initial Torque
Steering Gear To Frame 45 33 398
Second Torque
Then additional 90° turn
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LINKAGE 19 - 9

LINKAGE

TABLE OF CONTENTS

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LINKAGE
DIAGNOSIS AND TESTING - OUTER TIE ROD
END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS - TORQUE CHART . . . . . . . . . 9
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . 10
TIE ROD END
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REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10

LINKAGE
DIAGNOSIS AND TESTING - OUTER TIE ROD END

NOTE: If the outer tie rod end is equipped with a lubrication fitting, grease the joint then road
test the vehicle before performing test.

(1) Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as
possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight.
(2) Remove the front tires.
(3) Mount a dial indicator solidly to the vehicle steering knuckle and then zero the dial indicator.
(4) Position indicator plunger on the topside of the outer tie rod end.

NOTE: The dial indicator plunger must be perpen- dicular to the machined surface of the outer tie
rod end.

(5) Position a pry bar in order to pry downwards on the outer tie rod end.
(6) If the travel exceeds 0.5 mm (0.020 in.), replace the outer tie rod end (Refer to 19 - STEERING/
LINKAGE/TIE ROD END - REMOVAL).
(7) If the outer tie rod end is within specs reinstall the front tires (Refer to 22 - TIRES/WHEELS/
WHEELS - STANDARD PROCEDURE).

SPECIFICATIONS - TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


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Outer Tie Rod End Nut 130 96 —


Outer Tie Rod End 50 37 —
Lock- ing Nut
Steering Gear Boot 7 — 62
Clamp
19 - 10 LINKAGE
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SPECIAL TOOLS

FRONT SUSPENSION

Puller Tie Rod C-3894-A


TIE ROD END
REMOVAL
(1) Raise and support the vehicle. (2) Remove the front wheels.
(3) Loosen the lock nut (Fig. 1).
(4) Remove the tie rod end retaining nut (Fig. 1). (5) Separate the tie rod end from the steering
knuckle (Fig. 1) using special tool C-3894– A.
(6) Remove the outer tie rod end from the inner tie rod end by unscrewing (Fig. 1).
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Fig. 1 OUTER TIE ROD END


1 - OUTER TIE ROD END RETAINING NUT
2 - TIE ROD SEPERATOR TOOL
3 - OUTER TIE ROD END
4 - LOCKING NUT
5 - INNER TIE ROD END

INSTALLATION
(1) Install the outer tie rod end by screwing it onto thew inner tie rod end (Fig. 1).
(2) Install the outer tie rod end into the steering knuckle (Fig. 1).
(3) Tighten the outer tie rod end nut (Fig. 1). Tighten to 130 N·m (96 ft. lbs.).
(4) Install the front wheels. (5) Lower the vehicle.
(6) Perform toe adjustment.
(7) Tighten the lock nut after toe adjustment (Fig.
1). Tighten to 50 N·m (37 ft. lbs.).

PUMP 19 -
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PUMP
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PUMP

TABLE OF CONTENTS

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PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 11
STANDARD PROCEDURE
STANDARD PROCEDURE - POWER
STEERING PUMP - INITIAL OPERATION . . . . 11
STANDARD PROCEDURE - FLUSHING
POWER STEERING SYSTEM . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIFICATIONS - TORQUE CHART . . . . . . . . 13
FLUID
STANDARD PROCEDURE
POWER STEERING PUMP FILL AND BLEED PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 13
FLUID COOLER TUBE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HOSES
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REMOVAL
REMOVAL - PRESSURE HOSE . . . . . . . . . . . 14
REMOVAL - RETURN LINE FROM PUMP TO COOLER TUBE . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL - RETURN HOSE FROM GEAR
TO COOLER TUBE . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION
INSTALLATION - PRESSURE HOSE . . . . . . . 14
INSTALLATION - RETURN LINE FROM
PUMP TO COOLER TUBE . . . . . . . . . . . . . . . 14
INSTALLATION - RETURN HOSE FROM
GEAR TO COOLER TUBE . . . . . . . . . . . . . . . 14

PUMP
DESCRIPTION
CAUTION: Use approved fluid only in the power steering system (Refer to LUBRICATION &
MAINTE- NANCE/FLUID TYPES - DESCRIPTION). No other power steering or automatic
transmission fluid is to be used in the system. Damage may result to the power steering pump
and system if any other fluid is used, and do not overfill.

The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a
pressed-on pulley that is belt driven by the crankshaft pulley.
All vehicles are equipped with a power steering fluid cooler.

NOTE: Power steering pumps are not interchange- able with pumps installed on other vehicles.

OPERATION
Hydraulic pressure is provided for the power steer- ing gear by the belt driven power steering pump. The power
steering pumps are constant flow rate and dis- placement, vane-type pumps.
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DIAGNOSIS AND TESTING - PUMP LEAKAGE


The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and the
reservoir o-rings can be replaced.
Check for leaks in the following areas:
• Pump shaft seal behind the pulley
• Pump to reservoir O-ring
• Reservoir cap
• Pressure and return lines
• Flow control valve fitting

STANDARD PROCEDURE

STANDARD PROCEDURE - POWER STEERING PUMP - INITIAL OPERATION


WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.

CAUTION: Use approved fluid only in the power steering system (Refer to LUBRICATION &
MAINTE- NANCE/FLUID TYPES - DESCRIPTION). No other power steering or automatic
transmission fluid is to be used in the system. Damage may result to the power steering pump
and system if any other fluid is used, and do not overfill.

Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at
normal temperature.
(1) Turn steering wheel all the way to the left
(2) Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes.
(3) Raise the front wheels off the ground.

(4) Slowly turn the steering wheel lock-to-lock 20 times with the engine off while checking the fluid level.
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NOTE: For vehicles with long return lines or oil coolers turn wheel 40 times.

(5) Start the engine. With the engine idling main- tain the fluid level.
(6) Lower the front wheels and let the engine idle for two minutes.
(7) Turn the steering wheel in both direction and verify power assist and quiet operation of the pump. If the
fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat
the procedure.

CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump
damage.

STANDARD PROCEDURE - FLUSHING POWER STEERING SYSTEM


Flushing is required when the power steering/hy- draulic booster system fluid has become contami- nated.
Contaminated fluid in the steering/booster system can cause seal deterioration and affect steer- ing
gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the ground until the wheels are free to turn.
(2) Remove the return line from the pump.

NOTE: If vehicle is equipped with a hydraulic booster remove both return lines from the pump.

(3) Plug the return line port/ports at the pump.


(4) Position the return line/lines into a large con- tainer to catch the fluid.
(5) While an assistant is filling the pump reservoir start the engine.
(6) With the engine running at idle turn the wheel back and forth.

NOTE: Do not contact or hold the wheel against the steering stops.

(7) Run a quart of fluid through the system then stop the engine and install the return line/lines.
(8) Fill the system with fluid and perform Steering Pump Initial Operation, (Refer to 19 - STEERING/ PUMP
- STANDARD PROCEDURE).
(9) Start the engine and run it for fifteen minutes then stop the engine.
(10) Remove the return line/lines from the pump and plug the pump port/ports.
(11) Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still
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contaminated, then flush the system again.


(12) Install the return line/lines and perform Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).

REMOVAL
(1) Remove the belt from the power steering pump. (2) Siphon as much power steering fluid as possi-
ble out of the reservoir.
(3) Remove the high pressure power steering hose at the pump (Fig. 1).
(4) Remove the return hose from the pump (Fig.
1).
(5) Remove the bolts securing the power steering pump to the engine (Fig. 1).

Fig. 1 POWER STEERING PUMP


1 - PUMP MOUNTING BOLT
2 - CLAMP
3 - RETURN HOSE
4 - HIGH PRESSURE HOSE
5 - O-RING
6 - PUMP RESERVOIR
7 - PUMP
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8 - PULLEY

9 - PULLEY BOLT

INSTALLATION
(1) Install the power steering pump to the engine and tighten the bolts (Fig. 1). Tighten to 21 N·m (15 ft.
lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(3) Install the return hose to the pump and tighten the clamp (Fig. 1).
(4) Install the high pressure hose to the pump
(Fig. 1). Tighten to 38 N·m (28 ft. lbs.).
(5) Fill the power steering fluid (Refer to 19 - STEERING/PUMP/FLUID - STANDARD PROCE- DURE).

SPECIFICATIONS - TORQUE CHART

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Power Steering Pump 21 15 185
To Timing Case
Cover/Sup- port
High Pressure Flexible 38 28 336
Hose To Power Steering
Pump
Power Steering Pulley 30 22 265
To
Pump
FLUID
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STANDARD PROCEDURE

POWER STEERING PUMP FILL AND BLEED PROCEDURE


(1) Remove the cap from the fluid reservoir. Check cap seal for damage and replace if needed.
(2) Fill the power steering pump with approved fluid (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION). Do not fill fluid beyond the MAX mark.
(3) Raise the vehicles front wheels off the ground. (4) With the engine off turn the steering wheel from right
to left. Perform this step until all the bubble formations can no longer be seen in the
power steering reservoir.
(5) Start the engine and turn the steering wheel with the engine at idle speed then shut the engine off and
check for correct oil level and no bubble in the system.
(6) Reinstall power steering cap tightly.
(7) Test the system for leaks and proper operation.

FLUID COOLER TUBE


REMOVAL
(1) Siphon as much power steering fluid as possi- ble out of the reservoir.
(2) Remove the grille (Refer to 23 - BODY/EXTE- RIOR/GRILLE - REMOVAL).
(3) Remove the left headlight assembly.
(4) Disconnect the return lines from the cooler tube.
(5) Remove the radiator clips (2).
(6) Remove the heat shield bolt for the turbo at the core support.
(7) Remove the right headlight assembly.
(8) Remove the core support bolts (4) and discon- nect the hood latch cable.
(9) Remove the fan bracket bolts (4) to the radiator
(Fig. 2).
(10) Remove the two upper screws for the con- denser (Fig. 2).
(11) Remove the condenser air dam shield.
(12) Remove the mounting screws for the cooler tube (Fig. 2).
(13) Remove the cooler tube from the vehicle.
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Fig. 2 FLUID COOLER TUBE


1 - MOUNTING SCREWS (4)
2 - FLUID COOLER
3 - ELECTRIC COOLING FAN

4 - A/C CONDENSOR

INSTALLATION
(1) Install the cooler tube to the vehicle.
(2) Install the cooler tube mounting screws (Fig.
2).
(3) Install the condenser air dam shield.
(4) Install the condenser upper mounting screws
(Fig. 2).
(5) Install the fan bracket bolts to the radiator
(Fig. 2).

(6) Install the core support bolts and reconnect the hood latch cable.
(7) Install the right headlight assembly.
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(8) Install the bolt for the turbo shield at the core support.
(9) Install the radiator clips.
(10) Install the return lines to the cooler tube. (11) Install the left headlight assembly.
(12) Install the grille assembly (Refer to 23 - BODY/EXTERIOR/GRILLE - INSTALLATION).
(13) Fill the power steering fluid (Refer to 19 - STEERING/PUMP/FLUID - STANDARD PROCE- DURE).

HOSES

REMOVAL

REMOVAL - PRESSURE HOSE


(1) Siphon as much power steering fluid as possi- ble out of the reservoir.
(2) Disconnect the pressure hose at the pump.
(3) Disconnect the pressure hose at the steering gear.
(4) Remove the pressure hose mounting bracket from the gear.
(5) Remove the pressure hose from the vehicle.

REMOVAL - RETURN LINE FROM PUMP TO COOLER TUBE


(1) Siphon as much power steering fluid as possi- ble out of the reservoir.
(2) Disconnect the return line at the pump.
(3) Remove the grille (Refer to 23 - BODY/EXTE- RIOR/GRILLE - REMOVAL).
(4) Remove the left headlight assembly.
(5) Disconnect the return line at the cooler tube. (6) Remove the return line from the vehicle.

REMOVAL - RETURN HOSE FROM GEAR TO COOLER TUBE


(1) Siphon as much power steering fluid as possi- ble out of the reservoir.
(2) Disconnect the return hose from the gear.
(3) Remove the grille (Refer to 23 - BODY/EXTE- RIOR/GRILLE - REMOVAL).
(4) Remove the left headlight assembly.
(5) Disconnect the return line at the cooler tube. (6) Remove the return line from the vehicle.
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INSTALLATION

INSTALLATION - PRESSURE HOSE


(1) Install the pressure hose to the vehicle.
(2) Reconnect the pressure hose at the steering gear. Tighten to 37 N·m (27 ft.lbs.).
(3) Install the pressure hose mounting bracket to the steering gear.
(4) Reconnect the pressure hose at the power steering pump. Tighten to 38 N·m (28 ft.lbs.).
(5) Fill the power steering fluid (Refer to 19 - STEERING/PUMP/FLUID - STANDARD PROCE- DURE).

INSTALLATION - RETURN LINE FROM PUMP TO COOLER TUBE


(1) Install the return line to the vehicle.
(2) Reconnect the return line at the cooler tube. (3) Install the left headlight assembly.
(4) Install the grille assembly (Refer to 23 - BODY/ EXTERIOR/GRILLE - INSTALLATION).
(5) Reconnect the return line at the power steering pump.
(6) Fill the power steering fluid (Refer to 19 - STEERING/PUMP/FLUID - STANDARD PROCE- DURE).

INSTALLATION - RETURN HOSE FROM GEAR TO COOLER TUBE


(1) Install the return line to the vehicle.
(2) Reconnect the return line at the cooler tube. (3) Install the left headlight assembly.
(4) Install the grille assembly (Refer to 23 - BODY/ EXTERIOR/GRILLE - INSTALLATION).
(5) Reconnect the return line at the power steering gear.
(6) Fill the power steering fluid (Refer to 19 - STEERING/PUMP/FLUID - STANDARD PROCEDURE).