Power Steering Pump: Service and Repair
REMOVAL
1. Disconnect negative battery cable.
2. Remove power steering pump reservoir fill cap.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.
3. Raise vehicle on hoist.
4. Place approved drain container under power steering hoses at steering gear.
5. Disconnect power steering hoses from the steering gear.
IMPORTANT: After removing power steering hoses from gear, do not rotate steering wheel since fluid will be forced out of gear.
6. Remove power steering hoses from steering gear and allow system to drain.
7. Use a box end wrench to relieve spring tension from accessory drive belt tensioner; remove belt from power steering pump pulley.
8. On vehicles equipped with variable assist, disconnect EVO electrical connector.
NOTICE: It is not necessary to remove the three power steering pump bracket to engine block bolts.
9. On DOHC (LL0) engine, loosen upper power steering pump bracket bolt at cylinder head.
a. Remove upper power steering pump bracket bolt at power steering pump.
b. Swing bracket aside.
10. Remove three power steering pump-to-bracket bolts only. Obtain access to bolts by rotating power steering pump pulley.
11. Remove pump (with hoses) from vehicle.
12. Remove pressure and return hoses from pump.
DISASSEMBLY
1. Remove power steering pump from vehicle, as previously outlined.
2. Remove reservoir retaining clips from reservoir assembly.
3. Remove reservoir from housing.
4. Remove O-ring seal from pump housing.
5. Remove pump pulley using Power Steering Pump Pulley Remover SA9162C (or equivalent).
Removal Of EVO Solenoid.:
6. On EVO equipped vehicles, remove EVO actuator assembly with EVO Power Steering Actuator Socket SA9116C (or equivalent).
7. Remove flow control valve and spring.
Fig. 5 Pump Retaining Ring Removal:
8. Remove retaining ring.
a. If difficulty is encountered, use a C-clamp (one side on end cover, the other on pump drive shaft) to depress end cover, easing removal of retaining ring. Make sure to insert a piece of wood (or other protective material) between the C-clamp and pump drive shaft.
b. Place a punch into the pump housing access hole and remove the retaining ring.
Fig. 6 Pump Internal Component Removal:
9. Gently push or tap on drive shaft to assist in removing end cover.
10. Remove the following internal pump parts, in two groups:
- Group 1: End cover, O-ring, pressure plate spring, pressure plate.
- Group 2: Drive shaft with pump rotor, pump vanes, pump ring, thrust plate, and shaft retaining ring.
Fig. 7 Pump Housing O-ring Seal, Dowel Pins And Driveshaft Seal Removal:
11. Remove the following parts from the pump housing:
a. O-ring seal.
b. Two dowel pins from pump housing.
c. Drive shaft seal.
Fig. 11 Pressure Plate Assembly:
12. Remove pressure plate, pressure plate spring, and O-ring from end cover.
Fig. 8 Removing Rotor, Vanes, Ring And Thrust Plate From Driveshaft:
13. Remove shaft retaining ring from drive shaft and discard.
14. Remove pump rotor, pump vanes, pump ring, and thrust plate from drive shaft.
15. Separate pump rotor, pump vanes, and pump ring.
16. Clean all parts in power steering fluid and dry.
IMPORTANT: Replace any damaged components. Do not attempt to remove damage with abrasive cleaners.
IMPORTANT: A wavy pattern on the pump ring face will be present with low mileage and should not be mistaken for premature wear.
17. Inspect pump ring, pump vanes, thrust plate, and drive shaft for scoring, pitting, or chatter marks.
ASSEMBLY
1. Lubricate new drive shaft seal with power steering fluid.
2. Install new drive shaft seal into pump housing using a suitably sized socket as a driver.
Fig. 9 Driveshaft/rotor/thrust Plate Assembly:
3. Install thrust plate and pump rotor onto drive shaft.
4. Install new shaft retaining ring onto drive shaft.
5. Install drive shaft/rotor/thrust plate assembly into housing.
Fig. 10 Pump Ring Dowel Pins & Pump Ring Assembly:
6. Install pump ring dowel pins into pump housing through thrust plate.
IMPORTANT: The pump ring face has an indentation on one side near the dowel hole. The ring must be installed with the indentation facing up. If the ring is installed upside down, the pump will not function.
7. Install pump ring (with holes correctly positioned onto dowel pins) into housing.
8. Install vanes into pump rotor. Vanes have a radius at both ends and may be installed in either direction.
9. Lubricate new pump housing O-ring with power steering fluid and install into groove in housing.
10. Align pressure plate dowel holes with dowel pins and install plate into housing.
Fig. 11 Pressure Plate Assembly:
11. Position pressure plate spring against pressure plate. The spring may be installed in either orientation.
12. Lubricate new end cover O-ring with fluid and install onto end cover.
13. Lubricate outer edge of end cover with power steering fluid.
14. Press end cover into pump housing.
IMPORTANT: Make sure that the retaining ring is fully seated in the housing groove. If difficulty is encountered, use a press as shown or a C-clamp (one side on end cover, the other on pump drive shaft) to depress end cover, easing installation of retaining ring. Make sure to insert a piece of wood (or other protective material) between the C-clamp and pump drive shaft.
15. Install retaining ring into groove in pump housing, with ring opening near, but not across, access hole in housing.
IMPORTANT: If vehicle has constant flow power steering, go to step 23.
EVO Solenoid Replacement.:
16. Install the three O-rings in their correct locations:
a. Largest (19.00/18.54 mm ID) first
b. Mid-size (17.4/16.44 mm ID) second
c. Smallest (14.6/15.3 mm ID) third
17. Install discharge fitting to EVO actuator until fully seated.
18. Install flow control valve spring and valve into pump housing. Orientation of valve must be as shown in illustration to function correctly.
Removal Of EVO Solenoid.:
19. Correctly position EVO actuator and discharge fitting to pump assembly.
20. Using EVO Power Steering Actuator Socket SA9116C (or equivalent), tighten EVO actuator.
Torque: 62 Nm (46 ft. lbs.)
21. Position electrical connector so that it is in line with the pump shaft and pointing to the rear and install locating clip.
22. Install pump pulley using Power Steering Pump Pulley Installer SA9162C (or equivalent).
23. Lubricate new reservoir O-ring seal with power steering fluid and install onto reservoir.
24. Install reservoir into pump housing. Make sure to push reservoir straight into housing.
25. Install reservoir retaining clips.
26. Install pump into vehicle as described in next section.
27. Bleed system. (Refer to "Power Steering System Bleed Procedure".)
INSTALLATION
1. Inspect O-ring seals on each end of the pressure hose and on the gear end of the return hose and replace if necessary. Install pressure and return hoses onto pump.
Pressure Hose:
Torque: 27.5 Nm (20 ft. lbs.)
IMPORTANT: Do not tighten any of the bolts until all bolts have been started.
2. Position pump with hose against cylinder head and loosely install all bolts. Install the power steering pump bracket-to-cylinder head support brace bolts first on the DOHC (LL0) engine.
3. Torque the three power steering pump-to-bracket bolts.
Torque: 30 Nm (22 ft. lbs.)
4. On the DOHC (LL0) engine, torque the support bracket bolt to power steering pump first; then torque the upper support bracket bolt at the cylinder head.
Torque: 30 Nm (22 ft. lbs.)
(Applies to both ends of bracket.)
5. On vehicles equipped with variable assist, connect the EVO electrical connector.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.
6. Raise vehicle on hoist.
7. Install pressure and return hoses into steering gear.
Torque: 27.5 Nm (20 ft. lbs.)
8. Route hoses into the steering gear hose retaining clip, return hose first, pressure hose next. Secure hose in clip.
9. Lower vehicle from hoist.
NOTICE: Never overfill the power steering pump reservoir. Overfilling may cause contamination to accessory drive belt, generator, etc., resulting in premature failure.
10. Fill power steering pump fluid reservoir with clean power steering fluid. Install reservoir fill cap.
11. Install the accessory drive belt.
12. Connect negative battery cable.
Torque: 17 Nm (13 ft. lbs.)
13. Bleed power steering system. (Refer to "Power Steering Bleed Procedure".)