Repair Procedure

This bulletin involves installing revised power steering pressure and return lines.

WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST.

1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power steering fluid reservoir cap.

2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.

3. Raise the vehicle on an appropriate hoist.





4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1.

5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow the power steering fluid to drain into the pan.

6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle. Save the bracket and fastener for reuse.





7. Remove the power steering fluid return line screw clamp & hose from the power steering pump return line fitting and the power steering fluid return line tube from the steering gear, Figure 2. Discard the line and screw clamp.





8. Remove the power steering fluid pressure line from the power steering pump pressure fitting, Figure 3.

9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2. Remove and discard the power steering pressure line.

10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised power steering return line, p/n 05011873AA fittings to the steering gear.





NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE POWER STEERING RETURN LINE.

11. Route the power steering pressure line so it is over top of the power steering pump return tube and loosely install the power steering pressure line fitting to the power steering pump.

12. Install the bracket removed in step 6 around both the power steering pressure and return lines. Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.).

13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of the bracket attaching the power steering lines to the front suspension cradle and just to the right of the convoluted tubing on the return line, Figure 4.

14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the hose end of the power steering return line on to the power steering pump return fitting. Position the clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw to 2 Nm (18 in. lbs.).

15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with surrounding components.

16. Rotate the power steering pressure line until it is against the power steering pump return fitting and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)

17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in. lbs.) Figure 2.

18. POWER STEERING FLUID LEVEL ADJUSTMENT

NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.

a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark (ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.

b. Start the engine and let it run for 10 seconds and turn it off.

c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary and let the fluid settle for at least 2 minutes.

d. Raise the front wheels off the ground.

e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn stops.

f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary.

g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.

h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary.

i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.

19. Verify correct steering operation and no fluid leaks.

NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL LESSEN CONSIDERABLY WITH ADDED MILEAGE.