Power Steering Pump Replacement

REMOVAL





1. Remove the accessory drive belt.





2. Unclip the power steering hoses from the steering gear. The extra hose length allows the pump to be laid on the intake manifold for generator access and removal.

NOTICE: Prior to removing the power steering pump assembly, remove the fluid from the reservoir with a' hand held fluid suction gun. If the pump assembly is being replaced, always disconnect the fluid lines at the steering gear and allow them to completed drain. Rubber/plastic caps should be installed over the line ends to prevent fluid leakage. Place a shop towel over the generator and remove the pump assembly. Do not allow power steering fluid to contact the generator.






NOTICE: Do not remove the attachment bracket bolts from the pump assembly. Access has been provided through the oval pulley holes for socket clearance. Do not remove the lower tubular support bracket from under the intake manifold.

a. Remove the upper and lower attachment brackets at the intake manifold (DOHC [LL0] engine only).
b. Remove the bracket attachment bolts to the cylinder head and block. The DOHC (LL0) engine bracket has one extra attachment under the pulley bolt at the 6 o'clock position.
c. Lift the pump slightly and disconnect the E,1O electrical wire connector (DOHC [LL0] engine only).






3. Remove the pump assembly with brackets attached and lay it on the intake manifold.

IMPORTANT: Lay shop towels on the cam/rocker cover to prevent surface damage.

INSTALLATION





1. Hold the pump in place and connect the EVO wire connector.
2. Position pump with bracket against cylinder head and loosely install all bolts. Always install the lower power steering pump bracket-to-intake support brace first on the DOHC (LL0) engine.

NOTICE: Do not tighten any of the bolts until all bolts (three bolts for the SOHC [L24] engine and five bolts for the DOHC [LL0] engine) have been started.

3. Torque the three outer power steering bracket [bolts at front of engine.
4. On the DOHC (LL0) engine, tighten the lower support bracket bolts to power steering pump and then tighten the nut under the intake manifold if loosened.

Power Steering Pump Bracket to Block:
- Torque: 38 Nm (28 ft. lbs.)

Power Steering Pump Lower/Upper Support Brackets to Pump:
- Torque: 30Nm (22 ft. lbs.)

Power Steering Pump Upper Support Brackets to Pump and Upper/Lower Support Bracket to Intake Manifold:
- Torque: 30Nm (22 ft. lbs.)


5. On the DOHC (LL0) engine, torque upper support bracket bolt to power steering pump first and then torque the intake manifold brace bolt.
6. Make sure the hoses are properly positioned and secure them to the steering gear.

NOTICE: Never overfill the power steering pump reservoir. Overfilling may cause contamination to accessory drive belt, generator, etc.., thus resulting in premature belt failure.

7. Fill the power steering pump reservoir to the proper level (FULL) with new fluid. Do not overfill the reservoir.

NOTICE: Make sure the belt is properly aligned on the pulleys.

8. Install the accessory drive belt.
9. Start the vehicle and rotate the steering wheel full left and right several times to purge the system of air.
10. Check the system for leaks and make sure the power steering pumps reservoir is filled to the proper level. Do not overfill the reservoir