PL STEERING 19 - 1

STEERING
CONTENTS

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 35

POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 9 STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 26

GENERAL INFORMATION

INDEX
page page

GENERAL INFORMATION DIAGNOSIS AND TESTING

STEERING SYSTEM AND COMPONENT STEERING SYSTEM DIAGNOSIS CHARTS . . . . . 2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION meshing of the helical pinion teeth with the rack
teeth. Power assist steering is provided by an open
STEERING SYSTEM AND COMPONENT center, rotary type control valve. It is used to direct
DESCRIPTION oil from the power steering pump to either side of the
This vehicle comes with power steering as stan- integral steering rack piston.
dard equipment and is the only steering system Road feel is controlled by the diameter of a torsion
available. bar which initially steers the vehicle. As steering
The power steering system consists of these six effort increases as in a turn, the torsion bar twists,
major components. Power Steering Pump, Power causing relative rotary motion between the rotary
Steering Gear, Power Steering Reservoir, Power valve body and valve spool. This movement directs
Steering Supply and Pressure Hoses, and Power oil behind the integral rack piston, which in turn,
Steering Fluid Return Hose. Turning of the steering builds up hydraulic pressure and assists in the turn-
wheel is converted into linear travel through the ing effort.
19 - 2 STEERING PL

DIAGNOSIS AND TESTING at standstill parking. Hiss is a very high frequency

noise similar to that experienced while slowly closing
STEERING SYSTEM DIAGNOSIS CHARTS a water tap. The noise is present in every valve and
results in high velocity fluid passing valve orifice
STEERING NOISE edges. There is no relationship between this noise
There is some noise in all power steering systems. and performance of the steering. Hiss may be
One of the most common is a hissing sound evident expected when steering wheel at end of travel or
slowly turning at standstill.

CONDITION POSSIBLE CAUSES CORRECTION

Objectionable Hiss Or Whistle 1. Damaged or mispositioned 1. Check for proper seal between
steering column coupler to dash steering column coupler and dash
panel seal. seal.
2. Noisy valve in power steering 2. Replace steering gear assembly.
gear.
Rattle Or Clunk 1. Steering gear loose on front 1. Check steering gear to front
suspension crossmember. suspension crossmember mounting
bolts. Tighten to the specified torque
if found to be loose.
2. Front suspension crossmember to 2. Tighten the front suspension
frame bolts or studs loose. crossmember attaching bolts or
studs to the specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for
wear. Replace worn/loose parts as
required.
4. Loose lower control arm to front 4. Tighten control arm mounting
suspension crossmember bolts. bolts to the specified torques.
5. Loose strut assembly to body 5. Check upper strut mount to body
attaching bolts or nuts. attaching bolts or nuts for looseness.
If required, tighten to the specified
torques.
6. Power steering fluid pressure 6. Adjust hose to proper position by
hose touching the body of the loosening, repositioning, and
vehicle. tightening fitting to specified torque.
Do not bend tubing.
7. Noise internal to power steering 7. Replace steering gear assembly.
gear.
8. Damaged front suspension 8. Replace front suspension
crossmember. crossmember.
Chirp or squeal (in the area of the 1. Loose power steering pump drive 1. Adjust power steering pump drive
power steering pump). Particularly belt. belt to specified tension.
noticeable at full wheel travel and
during standstill parking.
PL STEERING 19 - 3
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

Power steering pump growl results from the development of high pressure fluid flow. Normally this noise should
not be high enough to be objectionable. Abnormal situations, such as a low oil level causing aeration or hose
touching the vehicle body, can create a noise level that could bring complaints.
Whine Or Growl (Pump Noise) 1. Low fluid level. 1. Fill power steering fluid reservoir
to proper level and perform leakage
diagnosis. (Recheck fluid level after
power steering fluid is free of air.)
2. Power steering hose touching 2. Reposition power steering hose.
vehicle body or frame. Replace hose if tube ends are bent.
3. Extreme wear of power steering 3. Replace power steering pump and
pump internal parts. flush system.
Sucking Air Sound 1. Loose clamp on power steering 1. Tighten or replace hose clamp.
fluid low pressure hose.
2. Missing O-Ring on power steering 2. Inspect connection and replace
hose connection. O-Ring as required.
3. Low power steering fluid level 3. Fill power steering fluid reservoir
to proper level and perform leakage
diagnosis.
4. Air leak between power steering 4. Inspect and or replace power
fluid reservoir and power steering steering fluid reservoir as required.
pump.
SQUEAK OR RUBBING SOUND 1. Sound coming from steering 1.Check for squeak in steering
column. column. Inspect for contact between
shroud, intermediate shaft, column,
and steering wheel. Realign if
necessary.
2. Check for lack or grease on
steering column dash panel to lower
coupler seal.
2. Sound internal to steering gear. 1. Replace steering gear assembly.
SCRUBBING OR KNOCKING 1. Incorrect tire size. 1. Verify that tire size on vehicle is
SOUND the same as originally supplied.
2. Check clearance between tires 2. Correct as necessary.
and other vehicle components,
through the full travel of the
suspension.
3. Check for interference between 3.Correct as necessary.
steering gear and other
components.
4.Incorrect steering gear supplied. 4. Replace steering gear with correct
steering gear for specific vehicle.
19 - 4 STEERING PL
DIAGNOSIS AND TESTING (Continued)
BINDING STICKING SEIZED

CONDITION POSSIBLE CAUSES CORRECTION

CATCHES, STICKS IN CERTAIN 1. Low power steering fluid level. 1. Fill power steering fluid reservoir
POSITIONS OR IS DIFFICULT TO to specified level and perform
TURN. leakage diagnosis.
2. Tires not inflated to specified 2. Inflate tires to the specified
pressure. pressure.
3. Lack of lubrication in front 3. Lubricate ball joints if ball joints
suspension control arm ball joints. are not a lubricated for life type ball
joint. If ball joint is a lubricated for
life ball joint, replace ball joint or
control arm.
4. Lack of lubrication in front 4. Lubricate tie rod ends if they are
suspension outer tie rod ends. not a lubricated for life type. If tie rod
end is a lubricated for life type,
replace tie rod end.
5. Loose power steering pump drive 5. Tighten the power steering pump
belt. drive belt to the specified tension.
See accessory drive in service
manual.
6. Faulty power steering pump flow 6. Replace power steering pump.
control. (Verify cause using Power
Steering Pump Test Procedure.)
7. Excessive friction in steering 7. Correct condition. (See Steering
column or intermediate shaft. Column Service Procedure)
8. Steering column coupler binding. 8. Realign the steering column to
eliminate the binding condition.
9. Binding upper strut bearing. 9. Correct binding condition in strut
bearing.
10 Excessive friction in steering 10 Replace steering gear assembly.
gear.

SHAKE SHUDDER VIBRATION

CONDITION POSSIBLE CAUSES CORRECTION

VIBRATION OF THE STEERING 1. Air in the fluid of the power 1. Steering shudder can be expected
WHEEL AND/OR DASH DURING steering system. in new vehicles and vehicles with
DRY PARK OR LOW SPEED recent steering system repairs.
STEERING MANEUVERS. Shudder should improve after the
vehicle has been driven several
weeks.
2. Tires not properly inflated. 2. Inflate tires to the specified
pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end. 4. Check that the inner to outer tie
rod jam nut for is tight. If required,
tighten the jam nut to the specified
torque.
5.Overcharged air conditioning 5.Check air conditioning pump head
system. pressure. (See Air Conditioning
Refrigerant System Diagnosis)
PL STEERING 19 - 5
DIAGNOSIS AND TESTING (Continued)
LOW ASSIST, NO ASSIST, HARD STEERING

CONDITION POSSIBLE CAUSES CORRECTION

STIFF, HARD TO TURN, 1. Tires not properly inflated. 1. Inflate tires to specified pressure.
SURGES, MOMENTARY
INCREASE IN EFFORT WHEN
TURNING.
2. Low power steering fluid level. 2. Add power steering fluid as
required to power steering fluid
reservoir to obtain proper level.
Perform leakage diagnosis on power
steering system.
3. Loose power steering pump drive 3. Adjust the power steering pump
belt. drive belt to the specified tension. If
drive belt is defective replace and
correctly tension.
4. Lack of lubrication in control arm 4. Lubricate ball joints if ball joints
ball joints. are not a lubricated for life type ball
joint. If ball joint is a lubricated for
life ball joint, replace ball joint or
control arm.
5. Low power steering pump 5. Verify cause using the Power
pressure. (Verify using Power Steering System Test Procedure.
Steering System Test Procedure) Replace the power steering pump if
necessary.
6. High internal leak in steering gear 6. Check steering system using the
assembly. Power Steering System Test
Procedure. If steering gear is
defective replace steering gear.
19 - 6 STEERING PL
DIAGNOSIS AND TESTING (Continued)
POOR RETURN TO CENTER

CONDITION POSSIBLE CAUSES CORRECTION

STEERING WHEEL DOES NOT 1. Tires not inflated to specified 1. Inflate tires to specified pressure.
WANT TO RETURN TO CENTER pressure.
POSITION.
2. Improper front wheel alignment. 2. Check and adjust as necessary.
3. Lack of lubrication in front 3. Lubricate ball joints if ball joints
suspension control arm ball joints. are not a lubricated for life type of
ball joint. If ball joint is a lubricated
for life ball joint, replace ball joint or
control arm.
4. Steering column U-joints 4. Realign steering column U-joints.
misaligned.
5. Mispositioned dash cover. 5. Reposition dash cover.
To evaluate items 6 and 7,
disconnect the intermediate shaft.
Turn the steering wheel and feel or
listen for internal rubbing in steering
column.
6. Steering wheel rubbing. 6. Adjust steering column shrouds to
eliminate rubbing condition.
7. Damaged, mis-positioned or 7. Determine condition which exists
un-lubricated steering column and correct.
coupler to dash seal.
8. Binding upper strut bearing. 8. Correct binding condition in strut
bearing.
9. Tight shaft bearing 9. Replace the steering column
in steering column assembly. assembly.
10. Excessive friction in steering 10. Replace steering column coupler.
column coupler.
11. Excessive friction in steering 11. Replace steering gear.
gear.
PL STEERING 19 - 7
DIAGNOSIS AND TESTING (Continued)
LOOSE STEERING

CONDITION POSSIBLE CAUSES CORRECTION

EXCESSIVE STEERING WHEEL 1. Air in the fluid of the power 1. Fill power steering fluid reservoir
KICKBACK OR TO MUCH steering system. to the specified level. Perform
STEERING WHEEL FREE PLAY. procedure to bleed the air out of the
power steering system. Perform
leakage diagnosis.
2. Steering gear loose on front 2. Check steering rear to front
suspension crossmember. suspension crossmember mounting
bolts. Tighten to specified torque if
found to be loose.
3. Worn, broken or loose steering 3. Check for worn universal joint,
column to steering gear coupler. broken isolator or loose fasteners.
4. Free play in steering column. 4.Check components of the steering
system and repair or replace as required.
5. Loose front suspension control 5. Check and or replace the ball joint
arm ball joints. or control arm as required.
6. Loose steering knuckle to ball 6. Check pinch bolts and tighten if
joint stud pinch bolt. required to specified torque.
7. Front wheel bearings loose or 7. Tighten hub nut to specified
worn. torque or replace with new parts as
necessary.
8. Loose outer tie rod ends. 8. Check free play of outer tie rod
ends and replace if required.
9. Loose inner tie rod ends. 9. Replace steering gear assembly.
10 Defective steering gear rotary 10. Replace steering gear assembly.
valve.

VEHICLE LEADS TO THE SIDE

CONDITION POSSIBLE CAUSES CORRECTION

STEERING WHEEL DOES NOT 1. Radial tire lead. 1.Rotate tires as recommended in
WANT RETURN TO CENTER the Tire And Wheel Group of this
POSITION. service manual.
2. Front suspension misaligned. 2. Align the front suspension as
required. Refer to the Wheel
Alignment Procedure in the
Suspension Group of this service
manual for the required wheel
alignment procedure.
3. Wheel braking. 3. Check for dragging brakes. Refer
to the procedures in the Brake
Group of this service manual.
4. Unbalanced steering gear valve. (If 4. Replace steering gear.
this is the cause, the steering efforts will
be very light in direction of lead and
heavier in the opposite direction.
STEERING WHEEL HAS FORE 1. Steering wheel to steering column 1. Tighten the retaining nut to its
AND AFT LOOSENESS. shaft retaining nut not properly specified torque specification.
tightened and torqued.
2. Steering column lower bearing 2. Replace steering column.
spring retainer slipped on steering
column shaft.
19 - 8 STEERING PL
DIAGNOSIS AND TESTING (Continued)
POWER STEERING FLUID LEAK

CONDITION POSSIBLE CAUSES CORRECTION

LOW FLUID LEVEL WITH: NO 1. Overfilled power steering pump 1. Adjust the power steering fluid fill
VISIBLE SIGNS OF A LEAK ON fluid reservoir. to the correct level.
THE STEERING GEAR, POWER
STEERING PUMP, FLOOR OR
ANYWHERE ELSE.
LOW FLUID LEVEL WITH: 2. Power steering hose connections 2. Check for loose fittings and if
VISIBLE LEAK ON STEERING at the power steering pump or found, tighten the fitting to its
GEAR, POWER STEERING steering gear. specified torque. If fittings are tight
PUMP, FLOOR OR ANYWHERE examine the fittings for damaged or
ELSE. missing O-ring seals and replace as
required.
3. Power steering pump or power 3. Identify the location of the leak
steering gear leaking. and repair or replace the component
as required. Refer to Power Steering
Pump and/or Power Steering Gear in
this group of the service manual for
required procedures.

FOAMY OR MILKY POWER STEERING FLUID

CONDITION POSSIBLE CAUSES CORRECTION

AERATION AND OVERFLOW OF 1. Air leaks. 1. Check for an air leak into the
FLUID. power steering system as described
under Sucking Air Diagnosis and
correct condition.
2. Low fluid level. 2. Extremely cold temperatures may
cause power steering fluid aeration if
the power steering fluid is low. Add
power steering fluid as required to
bring level up to specification.
3. Cracked power steering pump 3. Remove power steering pump
housing. from vehicle and inspect the power
steering pump housing for cracks. If
a defect in the housing is found,
replace the power steering pump.
4. Water contamination. 4. Drain the power steering fluid
from the system if there is evidence
of contamination. Then refill the
system with fresh clean power
steering fluid.
PL STEERING 19 - 9

POWER STEERING PUMP

INDEX
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DESCRIPTION AND OPERATION POWER STEERING FLUID RETURN HOSE . . . . 15

POWER STEERING PUMP . . . . . . . . . . . . . . . . . 9 POWER STEERING FLUID SUPPLY HOSE
DIAGNOSIS AND TESTING RESERVOIR TO POWER STEERING PUMP . . 17
POWER STEERING SYSTEM TEST POWER STEERING PRESSURE SWITCH . . . . . 12
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 10 POWER STEERING PUMP (ALL ENGINES) . . . . 18
SERVICE PROCEDURES DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP POWER STEERING PUMP DRIVE PULLEY . . . . 22
FLOW CONTROL VALVE SEAL . . . . . . . . . . . . 11 POWER STEERING PUMP MOUNTING
POWER STEERING PUMP BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INITIAL OPERATION . . . . . . . . . . . . . . . . . . . . 11 SPECIFICATIONS
POWER STEERING PUMP POWER STEERING PUMP FASTENER
SUCTION PORT SEAL . . . . . . . . . . . . . . . . . . 12 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 25
POWER STEERING SYSTEM POWER STEERING PUMP FLOW
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . 11 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION SPECIAL TOOLS
POWER STEERING FLUID PRESSURE HOSE . . 13 POWER STEERING PUMP . . . . . . . . . . . . . . . . . 25
POWER STEERING FLUID RESERVOIR . . . . . . 21

DESCRIPTION AND OPERATION All vehicles equipped with power steering use a
remote mounted reservoir for the power steering
POWER STEERING PUMP fluid. The power steering fluid remote reservoir is
On all vehicles equipped with power steering, the mounted to the rear of the cylinder head on the pas-
hydraulic pressure for operation of the power steer- senger side of the vehicle.
ing gear is provided by a belt driven power steering The service procedures for the TTA power steering
pump (Fig. 1). The TTA power steering pump is a pump are limited to the areas and components listed
constant flow rate and displacement, vane type pump below. No repair procedures are to be done on
internal components of the TTA power steering
pumps.
• Repair of power steering fluid leaks from areas
of the power steering pump sealed by O-rings is
allowed (See Pump Leak Diagnosis). However power
steering pump shaft seal leakage will require
replacement of the pump.
• Power steering fluid reservoirs, related compo-
nents and attaching hardware.
• Power steering fluid reservoir filler cap/dipstick
assemblies.
Because of unique shaft bearings, flow control lev-
els or pump displacements, power steering pumps
may be used only on specific vehicle applications. Be
sure that all power steering pumps are only replaced
with a pump that is the correct replacement for that
specific application.
Fig. 1 TTA Power Steering Pump Assembly Hydraulic pressure is provided for operation of the
. power steering gear by the belt driven power steering
In the event of a power steering pump drive belt pump id (Fig. 1). It is a constant displacement, vane
failure, manual steering control of the vehicle can type pump. The power steering pump is connected to
still be maintained. However, under these conditions, the steering gear by a power steering fluid pressure
steering effort will be significantly increased. hose and return hose.
19 - 10 STEERING PL
DESCRIPTION AND OPERATION (Continued)
Rectangular pumping vanes in the shaft driven
rotor, move power steering fluid from the intake to
the cam ring pressure cavities of the power steering
pump. As the rotor begins to turn, centrifugal force
throws the vanes against the inside surface of the
cam ring to pickup residual oil. This oil is then forced
into the high pressure area. As more oil is picked up
by the vanes, the additional oil is forced into the cav-
ities of the thrust plate through two crossover holes
in the cam ring and pressure plate. The crossover
holes empty into the high pressure area between the
pressure plate and the housing end cover.
As the high pressure area is filled, oil flows under
the vanes in the rotor slots, forcing the vanes to fol-
low the inside surface of the cam ring. As the vanes
reach the restricted area of the cam ring, oil is forced Fig. 2 Power Steering Pump Flow/Pressure Tester
out from between the vanes. When excess oil flow is POWER STEERING PUMP FLOW AND
generated during high-speed operation, a regulated PRESSURE TEST PROCEDURE
amount of oil returns to the pump intake side (1) Check power steering pump drive belt tension
through a flow control valve. The flow control valve and adjust as necessary.
reduces the power required to drive the pump and (2) Disconnect power steering fluid pressure hose,
holds down temperature build-up. at power steering pump. Use a container for dripping
When steering conditions exceed maximum pres- fluid.
sure requirements, such as when the wheels are (3) Connect Pressure Gauge, Special Tool from kit
turned against the stops. The pressure built up in 6815 (Fig. 3) to both hoses using adapter fittings.
the steering gear exerts pressure on the spring end of Connect spare pressure hose, to power steering pump
the flow control valve. The high pressure lifts the pressure hose banjo fitting.
relief valve ball from its seat and allows oil to flow
through a trigger orifice located in the outlet fitting.
This reduces pressure on the spring end of the flow
control valve which then opens and allows the oil to
return to the intake side of the pump. This action
limits maximum pressure output of the pump to a
safe level.
Under normal power steering pump operating con-
ditions, pressure requirements of the pump are below
maximum, causing the pressure relief valve to
remain closed.

DIAGNOSIS AND TESTING

POWER STEERING SYSTEM TEST PROCEDURE

The following procedure can be used to test the
operation of the power steering system on the vehi- Fig. 3 Power Steering Pump Flow/Pressure Tester
cle. This test will provide the flow rate of the power Connected To Power Steering Pump
steering pump along with the maximum relief pres-
(4) Completely open valve on Special Tool 6815
sure. This test is to be performed any time a power
(Fig. 3).
steering system problem is present to determine if
(5) Start engine and let idle long enough to circu-
the power steering pump or power steering gear is
late power steering fluid through flow/pressure test
not functioning properly. The following pressure and
and get air out of fluid. Then shut off engine.
flow test is performed using Pressure/Flow Tester,
(6) Check power steering fluid level, and add fluid
Special Tool 6815 (Fig. 2).
as necessary. Start engine again and let idle.
(7) Pressure gauge should read below 862 kPa
(125 psi), if above, inspect the hoses for restrictions
and repair as necessary. The initial pressure reading
PL STEERING 19 - 11
DIAGNOSIS AND TESTING (Continued)
should be in the range of 345-552 kPa (50-80 psi). POWER STEERING PUMP INITIAL OPERATION
The flow meter should read between 1.3 and 1.4
GPM CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
CAUTION: The following test procedure involves nents. Use only MoparT Power Steering Fluid. Do
testing power steering pump maximum pressure not use automatic transmission fluid. Do not over-
output and flow control valve operation. Do not fill.
leave valve closed for more than 5 seconds as the
pump could be damaged. Wipe filler cap clean, then check the fluid level.
The dipstick should indicate FULL COLD when the
(8) Close valve fully three times and record high- fluid is at normal temperature of approximately 21°C
est pressure indicated each time. All three read- to 27°C (70°F to 80°F).
ings must be above specifications and within (1) Fill the pump fluid reservoir to the proper level
345 kPa (50 psi) of each other. and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds.
NOTE: Power steering pump maximum relief pres- Then turn the engine off.
sure is 8240 to 8920 kPa (1195 to 1293 psi.). (3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
• If power steering pump pressures above specifi-
ning the engine.
cations but not within 345 kPa (50 psi) of each other,
(4) Raise the front wheels off the ground.
then replace power steering pump.
(5) Start the engine. Slowly turn the steering
• If pressures within 345 kPa (50 psi) of each
wheel right and left, lightly contacting the wheel
other but below specifications, then replace power
stops.
steering pump.
(6) Add power steering fluid if necessary.
CAUTION: Do not force the pump to operate (7) Lower the vehicle and turn the steering wheel
against the stops for more than 5 seconds at a time slowly from lock to lock.
because, pump damage will result. (8) Stop the engine. Check the fluid level and refill
as required.
(9) Open test valve. Turn steering wheel to the (9) If the fluid is extremely foamy, allow the vehi-
extreme left and right positions until against the cle to stand a few minutes and repeat the above pro-
stops, recording the highest indicated pressure at cedure.
each position. Compare pressure gauge readings to
power steering pump specifications. If highest output POWER STEERING PUMP FLOW CONTROL VALVE
pressures are not the same against either stop, the SEAL
steering gear is leaking internally and must be The power steering pump does not require removal
replaced. from the engine for removal and replacement of the
flow control valve fitting O-Ring.
SERVICE PROCEDURES REMOVE
(1) Remove the power steering fluid pressure hose
POWER STEERING SYSTEM FLUID LEVEL CHECK from the power steering pump pressure fitting (Fig.
4).
WARNING: FLUID LEVEL SHOULD BE CHECKED (2) Remove the flow control valve fitting from the
WITH ENGINE OFF TO PREVENT INJURY FROM power steering pump housing (Fig. 5). Prevent flow
MOVING PARTS. DO NOT USE AUTOMATIC TRANS- control valve and spring from sliding out of
MISSION FLUID IN THE POWER STEERING SYS- housing bore.
TEM. DO NOT OVERFILL THE POWER STEERING (3) Remove and discard O-ring seal from fitting.
SYSTEM.
INSTALL
Wipe reservoir filler cap free of dirt. Then check (1) If necessary, clean and install flow control
fluid level. The dipstick should indicate COLD when valve and spring in pump housing bore.
fluid is at normal ambient temperature, approxi- (2) Install new O-ring seal on fitting.
mately 21°C to 27°C (70°F to 80°F). In all pumps add (3) Install fitting in pump housing and tighten to
fluid as necessary, use only Mopar Power Steering 75 N·m (55 ft. lbs.)
Fluid, or equivalent. DO NOT USE ANY TYPE (4) Install power steering fluid pressure hose on
OF AUTOMATIC TRANSMISSION FLUID. flow control valve fitting.
19 - 12 STEERING PL
SERVICE PROCEDURES (Continued)

Fig. 4 Pressure Hose Attachment To Power Steering Fig. 6 Power Steering Pump Suction Port Fitting
Pump
(4) Remove and discard O-ring seal from suction
port fitting.

INSTALL
(1) Install new O-ring seal on suction fitting.
(2) Install suction port fitting in power steering
pump. Install and securely tighten the suction port
fitting attaching bolt.
(3) Install power steering fluid supply hose on suc-
tion port fitting, being sure hose clamp is installed on
hose past upset bead on suction port fitting.

REMOVAL AND INSTALLATION

POWER STEERING PRESSURE SWITCH
On vehicles equipped with power steering, a power
steering pressure switch is used to improve the vehi-
Fig. 5 Pump Discharge And Flow Control Valve cle’s idle quality. The pressure switch improves vehi-
Fitting cle idle quality, by controlling engine idle speed when
(5) Position locating pin on power steering pres- required.
sure hose banjo fitting so it is against power steering The pressure switch functions by signaling the
pump mounting bracket (Fig. 4). While holding locat- power train control module, that the power steering
ing pin against power steering pump bracket, torque system is putting additional load on the engine. This
banjo bolt to 34 N·m (25 ft. lbs.). type of condition exists when turning the front tires
of the vehicle, when the vehicle is stationary and the
POWER STEERING PUMP SUCTION PORT SEAL engine is at idle speed. When this condition is sensed
The power steering pump does not require removal by the power train control module, through a signal
from the engine for removal and replacement of the from the power steering pressure switch, engine idle
suction port O-Ring seal. speed is increased. This increase in engine idle speed
compensates for the additional load, thus maintain-
REMOVE ing the require engine idle speed and idle quality.
(1) Remove power steering fluid supply hose from The power steering pressure switch (Fig. 7) is
power steering pump suction port fitting (Fig. 6). mounted directly to the power steering gear on vehi-
(2) Remove bolt (Fig. 6) attaching power steering cle’s requiring its usage.
pump suction port fitting to the power steering
pump.
(3) Remove the suction port fitting (Fig. 6) from
the power steering pump.
PL STEERING 19 - 13
REMOVAL AND INSTALLATION (Continued)
REMOVE CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
CAUTION: When removing and installing the Steering Fluid, or equivalent.
power steering pressure switch, the use of a 7/8
inch deep well socket is required. The deep well (3) Fill power steering reservoir to correct fluid
socket will prevent damage to the plastic, electrical level.
connector area, of the power steering pressure (4) Connect negative cable back on negative post of
switch. battery.
(5) Start engine and turn steering wheel several
(1) Disconnect negative battery cable from the neg- times from stop to stop to bleed air from fluid in sys-
ative post of the battery. Be sure cable is isolated tem. Stop engine, check fluid level, and inspect sys-
from negative post on battery. tem for leaks. See Checking Fluid Level.
(2) Raise vehicle.
(3) Locate power steering pressure switch (Fig. 7) POWER STEERING FLUID PRESSURE HOSE
on back side of power steering gear.
CAUTION: Cap all open ends of hoses, power
steering pump fittings and steering gear ports to
prevent entry of foreign material into the compo-
nents.

WARNING: POWER STEERING OIL, ENGINE

PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.

For part reference and part location on the vehicle

being serviced, refer to the following figure numbers.
These figures show the hose bracket locations, hose
routings and fitting locations. Use these figure num-
Fig. 7 Power Steering Pressure Switch Location On bers when referring to the removal or installation
Steering Gear procedures for the power steering hoses listed below.
(4) Remove vehicle wiring harness connector (Fig. REMOVE
7), from power steering pressure switch. (1) Raise vehicle.
(5) Remove power steering pressure switch, from (2) Remove bolt attaching power steering hose
power steering gear. routing bracket to front suspension crossmember
(Fig. 8).
INSTALL

CAUTION: When installing the power steering

pressure switch in the steering gear, do not exceed
the torque specification shown in step 1 below.
Over-torquing will result in stripping the threads out
of the power steering pressure switch port on the
steering gear.

(1) By hand, install the power steering pressure

switch into the power steering gear until fully seated.
Then tighten the power steering pressure switch to a
maximum torque of 8 N·m (70 in. lbs.).
(2) Install vehicle wiring harness connector (Fig. 7)
onto power steering pressure switch. Be sure latch on
wiring harness connector is fully engaged with lock-
ing tab on power steering pressure switch.
Fig. 8 Power Steering Hose Routing Bracket
19 - 14 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(3) Disconnect power steering pressure hose (Fig.
9) at power steering gear. Drain power steering fluid
from power steering pump and hose through open
end of hose.

Fig. 11 Power Steering Hose Attachment To

Generator Shield

Fig. 9 Power Steering Pressure Hose At Steering

Gear
(4) Remove power steering pressure hose from
routing clip on generator shield (Fig. 10).

Fig. 12 Power Steering Hose Attachment To Power

Steering Pump
INSTALL
(1) Install power steering pressure hose in vehicle
from top of engine compartment.
(2) Using a lint free towel, wipe clean all open
Fig. 10 Power Steering Pressure Hose Routing Clip power steering hose ends, and the power steering
At Generator Shield pump and steering gear ports.
(5) Lower vehicle. (3) Install new O-ring on end of power steering
(6) Remove bolt, attaching power steering pressure pressure hose banjo fitting (Fig. 13).
hose routing clip, to generator shield (Fig. 11). (4) Install a new O-ring (Fig. 14) on power steering
(7) Loosen and remove Banjo bolt, and power pressure hose banjo fitting bolt.
steering pressure hose from pressure fitting on power (5) Lubricate both O-rings using fresh clean power
steering pump (Fig. 12). steering fluid.
(8) Power steering fluid pressure hose is removed (6) Install banjo bolt into the power steering pres-
from the vehicle from the top of the engine compart- sure hose banjo fitting (Fig. 14).
ment. (7) Attach power steering pressure hose to outlet
(9) Discard all used O-rings located at ends of fitting on power steering pump (Fig. 12). Do not
power steering pressure hose and Banjo bolt. tighten or torque pressure fitting Banjo bolt at
this time.
PL STEERING 19 - 15
REMOVAL AND INSTALLATION (Continued)
(11) Install the power steering pressure and return
hose routing clip on hoses (Fig. 8). Install bolt attach-
ing routing clip to front suspension crossmember.
Torque routing clip to front suspension crossmember
attaching bolt to 23 N·m (17 ft. lbs.)
(12) Torque power steering pressure hose to steer-
ing gear tube nut to 34 N·m (25 ft. lbs.).
(13) Install power steering pressure hose in rout-
ing clip on generator shield (Fig. 10).
(14) Lower Vehicle.
(15) Position locating pin on power steering pres-
sure hose banjo fitting so it is against power steering
pump mounting bracket (Fig. 12). While holding
locating pin against power steering pump bracket,
torque pump end Banjo bolt to 34 N·m (25 ft. lbs.).
(16) Securely tighten bolt attaching power steering
pressure hose bracket to generator shield.
Fig. 13 O-ring Installed On Power Steering Hose (17) Start the engine and let run for a few seconds.
Banjo Fitting Then turn the engine off.
(18) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(19) Raise front wheels of vehicle off the ground.
(20) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops. Then turn the engine off.
(21) Add power steering fluid if necessary.
(22) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(23) Stop the engine. Check the fluid level and
refill as required.
(24) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(25) After hose is installed, check for leaks at all
hose connections.
Fig. 14 O-ring Installed On Banjo Fitting Bolt
POWER STEERING FLUID RETURN HOSE
(8) Correctly route power steering pressure hose
avoiding tight bends or kinking of the hose. Install CAUTION: Cap all open ends of hoses, power
power steering pressure hose to generator shield steering pump fittings and steering gear ports to
routing clip attaching screw (Fig. 11) but do not prevent entry of foreign material into the compo-
tighten at this time. nents.
(9) Raise vehicle.

CAUTION: Hoses must remain away from exhaust WARNING: POWER STEERING OIL, ENGINE
system, vehicle components and unfriendly sur- PARTS AND EXHAUST SYSTEM MAY BE
faces causing possible damage to power steering EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
hoses. DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
(10) Route power steering pressure hose to pres- TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
sure port on power steering gear. Install power steer-
ing pressure hose, on steering gear and loosely
install tube nut into steering gear (Fig. 9). Tighten REMOVE
and torque tube nut after routing bracket is (1) Raise vehicle.
installed, correctly positioning hoses in vehicle. (2) Remove hose clamp, attaching return hose to
steel tube at power steering gear (Fig. 15). Let power
19 - 16 STEERING PL
REMOVAL AND INSTALLATION (Continued)
steering fluid, drain from return hose and power
steering fluid reservoir, until reservoir is empty.

Fig. 17 Tube Clip At Generator Shield

18). Then remove power steering return hose from
Fig. 15 Power Steering Return Hose At Steering power steering fluid reservoir.
Gear
(3) Remove power steering return hose from rout-
ing clip on generator shield (Fig. 16).

Fig. 18 Power Steering Return Hose At Reservoir

(7) Remove the power steering return hose from
the vehicle. The power steering return hose is
removed from the top of the engine compartment.
Fig. 16 Power Steering Hose Routing Clip At
Generator Shield INSTALL
(4) Lower vehicle. (1) Install power steering return hose on vehicle.
(5) Remove tube clip at generator shield (Fig. 17) Power steering return hose is installed from the top
attaching power steering fluid return hose to power of the vehicles engine compartment.
steering fluid pressure hose.
CAUTION: Care must be used when installing
CAUTION: Care must be used when removing power steering fluid return hose on power steering
power steering fluid return hose from power steer- fluid reservoir. If excessive force is used when try-
ing fluid reservoir. If excessive force is used when ing to install hose on nipple of power steering fluid
trying to remove hose from nipple on power steer- reservoir, nipple can be broken off the reservoir.
ing fluid reservoir, nipple can break off of the res-
ervoir. (2) Install power steering return hose on power
steering fluid reservoir fitting. Install hose clamp on
(6) Remove hose clamp, attaching power steering power steering return hose at power steering fluid
return hose to power steering fluid reservoir (Fig. reservoir (Fig. 18). Be sure hose clamp is
PL STEERING 19 - 17
REMOVAL AND INSTALLATION (Continued)
installed on return hose past upset bead on (Fig. 19). Then remove power steering fluid supply
power steering fluid reservoir. hose from power steering fluid reservoir.
(3) Raise vehicle.
(4) Clip power steering return hose and pressure
hose together (Fig. 17).
(5) Install power steering return hose on steel tube
at power steering gear (Fig. 15). Install hose clamp
on power steering return hose at power steering gear
(Fig. 15). Be sure hose clamp is installed on
return hose past upset bead on steel tube at
power gear.
(6) Install power steering return hose on routing
clip at generator shield (Fig. 16).
(7) Lower vehicle.
(8) Start the engine and let run for a few seconds.
Then turn the engine off.
(9) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine. Fig. 19 Power Steering Fluid Supply Hose At
(10) Raise front wheels of vehicle off the ground. Reservoir
(11) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel (2) Remove hose clamp, attaching power steering
stops. Then turn the engine off. fluid supply hose to the power steering pump (Fig.
(12) Add power steering fluid if necessary. 20). Then remove power steering fluid supply hose
(13) Lower the vehicle and turn the steering wheel from power steering pump fitting.
slowly from lock to lock.
(14) Stop the engine. Check the fluid level and
refill as required.
(15) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(16) After hose is installed, check for leaks at all
hose connections.

POWER STEERING FLUID SUPPLY HOSE

RESERVOIR TO POWER STEERING PUMP
WARNING: POWER STEERING OIL, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO Fig. 20 Power Steering Fluid Supply Hose At Power
TOUCH HOT EXHAUST MANIFOLD OR CATALYST. Steering Pump
(3) Remove power steering fluid supply hose from
REMOVE engine.

CAUTION: Care must be used when removing the INSTALL

power steering fluid supply hose from power steer- (1) Install power steering fluid supply hose back
ing fluid reservoir. If excessive force is used when on engine making sure it is correctly routed.
trying to remove hose from nipple on power steer-
ing fluid reservoir, nipple can break off of the res- CAUTION: Care must be used when installing
ervoir. power steering fluid supply hose on power steering
fluid reservoir. If excessive force is used when try-
(1) Remove hose clamp, attaching power steering ing to install hose on nipple of power steering fluid
fluid supply hose to power steering fluid reservoir reservoir, nipple can be broken off the reservoir.
19 - 18 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(2) Install power steering fluid supply hose on
power steering fluid reservoir fitting. Install hose
clamp on power steering fluid supply hose at power
steering fluid reservoir (Fig. 19). Be sure hose
clamp is installed on return hose past upset
bead on power steering fluid reservoir.
(3) Install power steering fluid supply hose on
power steering pump fitting. Install hose clamp on
power steering fluid supply hose at power steering
pump fitting (Fig. 20). Be sure hose clamp is
installed on power steering fluid supply hose
past upset bead on power steering pump fit-
ting.
(4) Start the engine and let run for a few seconds.
Then turn the engine off.
(5) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run- Fig. 21 Power Steering Hose Attachment To Power
ning the engine. Steering Pump
(6) Raise front wheels of vehicle off the ground.
(3) Discard all used O-rings on the power steering
(7) Start the engine. Slowly turn the steering
pressure hose Banjo fitting and Banjo bolt.
wheel right and left, lightly contacting the wheel
(4) Remove hose clamp attaching power steering
stops. Then turn the engine off.
fluid supply hose to the power steering pump suction
(8) Add power steering fluid if necessary.
fitting (Fig. 22). Remove power steering fluid supply
(9) Lower the vehicle and turn the steering wheel
hose from power steering pump fitting.
slowly from lock to lock.
(10) Stop the engine. Check the fluid level and
refill as required.
(11) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
(12) After hose is installed, check for leaks at all
hose connections.

POWER STEERING PUMP (ALL ENGINES)

WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES, OR ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
Fig. 22 Power Steering Fluid Supply Hose At Power
The power steering pump removal procedure and
Steering Pump
pump and bracket fastener locations are the same for
both engine applications used for this vehicle. The (5) Raise vehicle on jackstands or centered on a
front power steering pump bracket must be removed frame contact type hoist. See hoisting in the Lubrica-
as an assembly with the power steering pump and tion And Maintenance Section of this service manual
removed from the pump after removing the pulley for the required lifting procedure to be used for this
from the power steering pump. vehicle.

REMOVE NOTE: If the vehicle is equipped with a dual over-

(1) Remove battery cable from (-) negative post on head cam engine, the bolt attaching the coolant
battery. tube to the intake manifold needs to be removed.
(2) Remove Banjo Bolt and power steering fluid Refer to following step for required procedure.
pressure hose from pressure fitting on power steering
pump (Fig. 21). (6) Remove the bolt attaching the coolant tube
(Fig. 23) to the bottom of the intake manifold. The
PL STEERING 19 - 19
REMOVAL AND INSTALLATION (Continued)
bolt requires removal to allow the coolant tube
to be moved out of the way for access to the
power steering pump mounting bolt. The cool-
ant tube does not need to be removed or the
cooling system drained.

Fig. 25 Power Steering Pump Front Mounting

Bracket Bolt

Fig. 23 Coolant Tube To Intake Manifold Attachment

(7) Remove the 2 power steering pump to cast
bracket mounting and adjustment bolts (Fig. 24).

Fig. 26 Power Steering Pump And Bracket

(11) Transfer required parts from removed power
steering pump to replacement power steering pump.

INSTALL
(1) Install power steering pump and mounting
Fig. 24 Power Steering Pump Mounting Bolts (Rear) bracket as an assembly (Fig. 26) back on the engine
using reverse of removal procedure.
NOTE: The power steering pump front mounting (2) Slide front power steering pump bracket
bracket is slotted at the bolt attaching it to the front between bracket mounting bolt and front engine
engine mount (Fig. 25). This bolt only needs to be mount (Fig. 25). Be sure washer on bolt is
loosened to remove mounting bracket from engine. between the head of the bolt and bracket and
(8) Loosen bolt (Fig. 25) attaching the power steer- does not get trapped between bracket and
ing pump front mounting to the front engine mount engine mount.
only far enough to slide the bracket out from under (3) Install the 2 power steering pump to cast
the bolt. mounting bracket attaching bolts (Fig. 24). Do not
(9) Remove power steering pump drive belt from tighten bolts at this time.
power steering pump pulley. (4) Install power steering pump drive belt on
(10) Remove power steering pump and front power steering pump pulley.
mounting bracket as an assembly from the engine (5) Install a 1/2 in. breaker bar in the square hole
(Fig. 26). in the front power steering pump mounting bracket
(Fig. 27). Then rotate pump in to obtain the correct
19 - 20 STEERING PL
REMOVAL AND INSTALLATION (Continued)
drive belt tension. See Accessory Drive Belts in (9) Install a new O-ring (Fig. 29) on power steering
Group 7 Cooling System of this service manual for fluid pressure hose banjo fitting bolt.
the correct drive belt tension specification. When cor-
rect drive belt tension is obtained torque the 2 bolts
at the power steering pump cast mounting bracket
(Fig. 24) to 54 N·m (40 ft. lbs.). Then torque the front
power steering pump mounting bracket bolt (Fig. 25)
to 54 N·m (40 ft. lbs.).

Fig. 29 O-Ring Installed On Banjo Fitting Bolt

(10) Lubricate both O-rings using fresh clean
power steering fluid.
(11) Install banjo bolt into the power steering pres-
sure hose banjo fitting.
Fig. 27 Setting Power Steering Pump Drive Belt (12) Attach power steering pressure hose on outlet
Tension fitting of the power steering pump (Fig. 21).
(13) Position locating pin on power steering pres-
(6) Install power steering supply hose on power
sure hose banjo fitting so it is against power steering
steering pump suction fitting (Fig. 22). Install hose
pump mounting bracket (Fig. 21). While holding
clamp on hose, being sure hose clamp is installed on
locating pin against power steering pump bracket,
hose past upset bead on power steering pump tube.
torque pump end Banjo bolt to 34 N·m (25 ft. lbs.).
(7) Using a lint free towel, wipe clean all open
power steering hose ends, and power steering pump CAUTION: Do not use automatic transmission fluid
fittings. in power steering system. Only use MoparT, Power
(8) Install a new O-ring on the end of the power Steering Fluid, or equivalent.
steering pressure hose banjo fitting (Fig. 28).
(14) Fill power steering reservoir to correct fluid
level.
(15) Connect negative cable back on negative post
of battery.
(16) Start the engine and let run for a few seconds.
Then turn the engine off.
(17) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(18) Raise front wheels of vehicle off the ground.
(19) Start engine, then slowly turn steering wheel
right and left several times until lightly contacting
the wheel stops. Then turn the engine off.
(20) Add power steering fluid if necessary.
(21) Lower the vehicle. Start engine again and
turn the steering wheel slowly from lock to lock.
(22) Stop the engine. Check the fluid level and
Fig. 28 O-Ring Installed On Power Steering Hose refill as required.
Banjo Fitting
PL STEERING 19 - 21
REMOVAL AND INSTALLATION (Continued)
(23) If the fluid is extremely foamy, allow the vehi- NOTE: Removal of the CRS tank improves access
cle to stand a few minutes and repeat the above pro- to the power steering fluid reservoir attaching bolts.
cedure. (5) Remove the nut and screw attaching the CRS
(24) After power steering pump is installed, check tank to the dash panel (Fig. 32). Remove the CRS
for leaks at all hose connections and power steering tank from the dash panel and lower it down on top of
pump fittings. the steering gear toward the center of the vehicle.

POWER STEERING FLUID RESERVOIR

REMOVE
(1) Raise vehicle on jack stands or on a frame con-
tact type hoist. See Hoisting in the Lubrication And
Maintenance Section of this service manual for the
required lifting procedure to be used for this vehicle.
(2) Remove hose clamp, attaching return hose to
steel tube at power steering gear (Fig. 30). Let power
steering fluid drain from return hose and power
steering fluid reservoir, until reservoir is empty.

Fig. 32 CRS Tank Mounting Bolt And Screw

CAUTION: Care must be used when removing and
installing power steering fluid hoses on the power
steering fluid reservoir. If excessive force is used
when trying to remove or install hoses on nipples
of power steering fluid reservoir, nipples can be
broken off the reservoir.

(6) Remove the power steering fluid return and

supply hose from the power steering fluid reservoir
(Fig. 33).

Fig. 30 Power Steering Return Hose At Steering

Gear
(3) Lower vehicle.
(4) Remove the coolant overflow hose from the
coolant recovery system (CRS) tank (Fig. 31).

Fig. 33 Power Steering Fluid Hoses At Reservoir

(7) If vehicle is equipped with the single over-
head cam engine, remove the 3 bolts (Fig. 34)
attaching the power steering fluid reservoir to the
cylinder head.

Fig. 31 Overflow Hose Connection At CRS Tank

19 - 22 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(4) Install the coolant overflow hose from the cool-
ant recovery system (CRS) tank (Fig. 31)
(5) Raise vehicle.
(6) Install power steering return hose, on the steel
tube at the power steering gear (Fig. 30). Be sure
hose clamp is installed on hose past upset bead
on power steering gear steel tube.
(7) Fill power steering pump fluid reservoir to the
proper level.
(8) Start the engine and let run for a few seconds.
Then turn the engine off.
(9) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(10) Raise front wheels of vehicle off the ground.
(11) Start the engine. Slowly turn the steering
Fig. 34 Power Steering Fluid Reservoir Hoses And wheel right and left, lightly contacting the wheel
Mounting stops. Then turn the engine off.
(12) Add power steering fluid if necessary.
(8) If vehicle is equipped with the dual over-
(13) Lower the vehicle and turn the steering wheel
head cam engine, remove the 2 nuts (Fig. 35)
slowly from lock to lock.
attaching the power steering fluid reservoir to the
(14) Stop the engine. Check the fluid level and
cylinder head .
refill as required.
(15) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.

DISASSEMBLY AND ASSEMBLY

POWER STEERING PUMP DRIVE PULLEY
The power steering pump must be removed from
the vehicle for removal of the power steering pump
pulley. Refer to Power Steering Pump Removal in the
Power Steering Pump Service Procedures section in
this group of the service manual.

REMOVE
(1) Remove power steering pump from engine.
Refer to Power Steering Pump Removal in the Power
Fig. 35 Power Steering Fluid Reservoir Mounting
Steering Pump Service Procedures section in this
(9) Remove power steering fluid reservoir from group of the service manual for required procedure.
vehicle.
CAUTION: Do not hammer on power steering
INSTALL pump pulley or shaft to remove power steering
(1) Install power steering fluid reservoir on cylin- pump pulley. This will damage the pulley and the
der head. Install and securely tighten the power power steering pump.
steering fluid reservoir to cylinder head attaching
bolts (Fig. 34) or. (Fig. 35). (2) Mount power steering pump in a vise using the
(2) Install the power steering fluid return and sup- power steering pump mounting bracket (Fig. 36).
ply hose, on the power steering fluid reservoir fit- Install Puller, Special Tool C-4333 or C- 4068 on
tings (Fig. 33). Be sure both hose clamps are power steering pump pulley (Fig. 36). Remove the
installed on hose past upset bead on power power steering pump pulley from the power steering
steering reservoir fittings. pump shaft.
(3) Install engine coolant recovery system tank on (3) Replace power steering pump pulley if bent,
dash panel of vehicle. Install and securely tighten cracked, or loose.
attaching bolts (Fig. 32).
PL STEERING 19 - 23
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 36 Pulley Removal From Power Steering Pump

Shaft Fig. 38 Correctly Installed Power Steering Pump
Pulley
INSTALL
(3) Remove Installer, Special Tool C-4063 from
CAUTION: Do not hammer on power steering power steering pump.
pump pulley or shaft to remove power steering (4) Install power steering pump and mounting
pump pulley. This will damage the pulley and the bracket back on engine. Refer to Power Steering
power steering pump. Pump Installation in the Power Steering Pump Ser-
vice Procedures section in this group of the service
(1) Mount power steering pump in a vise using the manual for required procedure.
power steering pump mounting bracket (Fig. 37).
Then place power steering pump pulley squarely on POWER STEERING PUMP MOUNTING BRACKET
end of power steering pump shaft. Mount Installer,
Special Tool C-4063 in internal threads of the power DISASSEMBLE
steering pump shaft and against power steering (1) Remove power steering pump from engine.
pump pulley (Fig. 37). Refer to Power Steering Pump Removal And Instal-
lation in the Power Steering Pump section in this
group of the service manual for required procedure.

CAUTION: Do not hammer on power steering

pump pulley or shaft to remove power steering
pump pulley. This will damage the pulley and the
power steering pump.

(2) Mount the power steering pump in a vise using

the power steering pump mounting bracket (Fig. 39).
Mount Puller, Special Tool C-4333 or C- 4068 on
power steering pump pulley (Fig. 39). Remove the
power steering pump pulley from the power steering
pump shaft.
(3) Remove the 3 bolts attaching the power steer-
ing pump to the mounting bracket (Fig. 40).
(4) Remove power steering pump from mounting
Fig. 37 Pulley Installation On Power Steering Pump bracket.
Shaft ASSEMBLE
(2) Ensuring that special tool and pulley remain (1) Install power steering pump on mounting
aligned with pump shaft, force pulley onto power bracket. Install the 3 power steering pump mounting
steering pump shaft until flush with the end of the bolts (Fig. 40). Torque the 3 mounting bolts to 54
shaft (Fig. 38). When pulley is flush with shaft N·m (40 ft. lbs.).
tool will no longer be able to be turned.
19 - 24 STEERING PL
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 39 Pulley Removal From Power Steering Pump

Fig. 41 Installing Pulley On Power Steering Pump
Shaft
Shaft
steering pump shaft until flush with the end of the
shaft (Fig. 42). When pulley is flush with shaft
tool will no longer be able to be turned.

Fig. 40 Power Steering Pump Mounting Bolts

CAUTION: Do not hammer on power steering
pump pulley or shaft to remove power steering
pump pulley. This will damage the pulley and the
power steering pump. Fig. 42 Correctly Installed Power Steering Pump
Pulley
(2) Place power steering pump pulley squarely on
end of power steering pump shaft. Mount Installer, (4) Remove Installer, Special Tool C-4063 from
Special Tool C-4063 in internal threads of the power power steering pump.
steering pump shaft and against power steering (5) Install power steering pump and bracket
pump pulley (Fig. 41). assembly back on engine. Refer to Power Steering
(3) Ensuring that special tool and pulley remain Pump Installation in the Power Steering Pump Ser-
aligned with pump shaft, force pulley onto power vice Procedures section in this group of the service
manual for required procedure.
PL STEERING 19 - 25

SPECIFICATIONS SPECIAL TOOLS

POWER STEERING PUMP FLOW SPECIFICATIONS POWER STEERING PUMP

Power Steering Pump Flow:

At 1500 RPM And
Minimum Pressure. . . . . . . . .4.9 to 5.3 Liters/Min
(1.3 to 1.9 GPM)
Control Valve Pressure Relief . . . . 8240 to 8920 kPa
(1195 to 1293 psi)

POWER STEERING PUMP FASTENER TORQUE

SPECIFICATIONS
Installer C-4063B
DESCRIPTION TORQUE
Power Steering Hose:
Tube Nuts Pressure And Return . . . . . . . . . . .31 N·m
(275 in. lbs.)
Bracket To Front Crossmember
Attaching Bolt . . . . . . . . . . . . .23 N·m (17 ft. lbs.).
Power Steering Pump:
Pressure Hose Banjo Bolt . . . . . .34 N·m (25 ft. lbs.).
Discharge Fitting . . . . . . . . . . . . .75 N·m (55 ft. lbs.)
To Bracket Mounting Bolts . . . . .54 N·m (40. ft. lbs.)
Brackets To Engine Mounting Bolts . . . . . . . 54 N·m Puller C-4333
(40 ft. lbs.)

P/S System Analyzer 6815

19 - 26 STEERING PL

STEERING GEAR

INDEX
page page

DESCRIPTION AND OPERATION DISASSEMBLY AND ASSEMBLY

STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 26 OUTER TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . 32
DIAGNOSIS AND TESTING SPECIFICATIONS
POWER STEERING SYSTEM STEERING GEAR FASTENER
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . 27 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 34
REMOVAL AND INSTALLATION SPECIAL TOOLS
MANUAL AND POWER STEERING GEAR . . . . . 28 POWER STEERING GEAR . . . . . . . . . . . . . . . . . 34

DESCRIPTION AND OPERATION Road feel is controlled by the diameter of a torsion

bar which initially steers the vehicle. This movement
STEERING GEAR directs oil behind the integral rack piston, which, in
The power steering system consists of these four turn, builds up hydraulic pressure and assists in the
major components. Power Steering Gear (Fig. 1), turning effort.
Power Steering Pump, Pressure Hose, and Return The drive tangs on the pinion of the power steering
Line. Turning of the steering wheel is converted into pump mate loosely with a stub shaft. This is to per-
linear travel through the meshing of the helical pin- mit manual steering control to be maintained if the
ion teeth with the rack teeth. Power assist steering is drive belt on the power steering pump should break.
provided by an open center, rotary type control valve
which directs oil from the pump to either side of the
integral rack piston.

Fig. 1 Power Steering Gear Assembly

PL STEERING 19 - 27
DESCRIPTION AND OPERATION (Continued)
However, under these conditions, steering effort will
be increased.

NOTE: The power steering gear (Fig. 1) should NOT

be serviced or adjusted. If a malfunction or oil leak
occurs with the steering gear, the complete steering
gear needs to be replaced.

DIAGNOSIS AND TESTING

POWER STEERING SYSTEM TEST PROCEDURE
The following procedure can be used to test the
operation of the power steering system on the vehi-
cle. This test will provide the flow rate of the power
steering pump along with the maximum relief pres-
sure. This test is to be performed any time a power Fig. 3 Power Steering Pump Flow/Pressure Tester
steering system problem is present to determine if Connected To Power Steering Pump
the power steering pump or power steering gear is (6) Check power steering fluid level, and add fluid
not functioning properly. The following pressure and as necessary. Start engine again and let idle.
flow test is performed using Pressure/Flow Tester, (7) Pressure gauge should read below 862 kPa
Special Tool 6815 (Fig. 2). (125 psi), if above, inspect the hoses for restrictions
and repair as necessary. The initial pressure reading
should be in the range of 345-552 kPa (50-80 psi).
The flow meter should read between 1.3 and 1.4
GPM

CAUTION: The following test procedure involves

testing power steering pump maximum pressure
output and flow control valve operation. Do not
leave valve closed for more than 5 seconds as the
pump could be damaged.

(8) Close valve fully three times and record high-

est pressure indicated each time. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.

Fig. 2 Power Steering Pump Flow/Pressure Tester NOTE: Power steering pump maximum relief pres-
POWER STEERING PUMP FLOW AND sure is 8240 to 8920 kPa (1195 to 1293 psi.).
PRESSURE TEST PROCEDURE
(1) Check power steering pump drive belt tension • If power steering pump pressures above specifi-
and adjust as necessary. cations but not within 345 kPa (50 psi) of each other,
(2) Disconnect power steering fluid pressure hose, then replace power steering pump.
at power steering pump. Use a container for dripping • If pressures within 345 kPa (50 psi) of each
fluid. other but below specifications, then replace power
(3) Connect Pressure Gauge, Special Tool from kit steering pump.
6815 (Fig. 3) to both hoses using adapter fittings.
CAUTION: Do not force the pump to operate
Connect spare pressure hose, to power steering pump
against the stops for more than 5 seconds at a time
pressure hose banjo fitting.
because, pump damage will result.
(4) Completely open valve on Special Tool 6815
(Fig. 3). (9) Open test valve. Turn steering wheel to the
(5) Start engine and let idle long enough to circu- extreme left and right positions until against the
late power steering fluid through flow/pressure test stops, recording the highest indicated pressure at
and get air out of fluid. Then shut off engine. each position. Compare pressure gauge readings to
power steering pump specifications. If highest output
19 - 28 STEERING PL
DIAGNOSIS AND TESTING (Continued)
pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.

REMOVAL AND INSTALLATION

MANUAL AND POWER STEERING GEAR
The removal and replacement procedure for both
the manual and power steering gears is the same.
The only additional steps of the procedure for the
power steering gear, is the removal and replacement
of the power steering fluid lines at the steering gear.

REMOVE
(1) From interior of vehicle, disconnect the steer-
ing gear coupler, from the steering column shaft cou-
Fig. 5 Engine/Transaxle Bobble Dampener
pler (Fig. 4).

Fig. 4 Steering Column To Steering Gear Coupler Fig. 6 Removing Tie Rod End Attaching Nut
(2) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(3) Remove both front wheel and tire assemblies
from the vehicle.
(4) Remove engine/transaxle bobble dampener, on
vehicles so equipped, from front suspension cross-
member (Fig. 5). Bobble strut does not need to be
removed from transaxle assembly.
(5) Remove nuts attaching both outer tie rod ends
to the steering knuckles (Fig. 6). Nuts are to be
removed from tie rod ends using the following
procedure, hold tie rod end stud with an 11/32
socket, while loosening and removing nut with
wrench. Fig. 7 Tie Rod End Removal From Steering Knuckle
(6) Remove tie rod ends from steering knuckles (7) If equipped, remove vehicle wiring harness con-
using Remover, Special Tool MB-991113 (Fig. 7). nector from the power steering fluid pressure switch
(Fig. 8).
PL STEERING 19 - 29
REMOVAL AND INSTALLATION (Continued)

Fig. 8 Power Steering Fluid Pressure Switch Fig. 10 Power Steering Fluid Pressure And Return
Electrical Connector Hoses
(8) If vehicle is equipped with power steering, gage holes located in the underbody of the vehicle.
remove power steering pressure and return hose With this method of designing and building a vehi-
routing bracket from front suspension crossmember cle, it is no longer possible to adjust a vehicles
(Fig. 9). The hose routing bracket does not have front suspension alignment settings to the required
to be removed from the power steering pres- specifications. Due to this, whenever the front sus-
sure and return hoses. pension crossmember is removed from a vehicle, it
MUST be replaced in the same location on the body
of the vehicle it was removed from. Front suspen-
sion Toe settings though are still adjustable by the
outer tie rod ends.

CAUTION: Before removing front suspension

crossmember from the vehicle, the location of the
front suspension crossmember MUST be scribbed
on body of vehicle per (Fig. 9). This must be done
so crossmember can be relocated against body of
vehicle in the same location when it is reinstalled. If
location of front suspension crossmember to body
of vehicle is not maintained when vehicle is assem-
bled, NET BUILD front suspension alignment set-
tings will not be obtained. This may lead to
handling and or tire wear problems.
Fig. 9 Power Steering Pressure And Return Hose
Routing Bracket (10) Using an awl, scribe a line (Fig. 11) marking
the location of where front suspension crossmember
(9) If vehicle is equipped with power steering,
is mounted against the body of the vehicle.
remove power steering fluid, pressure and return
(11) Position a transmission jack under the center
hoses (Fig. 10) from the power steering gear assem-
of the front suspension crossmember (Fig. 12). Trans-
bly.
mission jack is used to lower, support and raise front
NOTE: This vehicle is designed and assembled suspension crossmember when removing steering
using NET BUILD front suspension alignment set- gear assembly.
tings. This means that front suspension alignment (12) Loosen and fully remove the front 2 bolts (Fig.
settings are determined as the vehicle is designed 13) attaching front suspension crossmember to frame
by the location of front suspension components in rails of vehicle. Then loosen the 2 rear bolts (Fig. 13)
relation to the vehicle body. This process is carried attaching front suspension crossmember and lower
out when building the vehicle, by accurately locat- control arm to body of vehicle. Lower front suspen-
ing the front suspension crossmember, to master sion crossmember while loosening rear bolts,
19 - 30 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(13) Using transmission jack, lower front suspen-
sion crossmember enough to allow steering gear to be
removed from crossmember (Fig. 14). When lower-
ing front suspension crossmember, do not let
crossmember hang from lower control arms
weight of crossmember should be supported by
transmission jack.

Fig. 11 Marking Front Suspension Crossmember

Location

Fig. 14 Crossmember Lowered For Removal Of

Steering Gear
(14) Loosen and remove the 4 bolts (Fig. 15),
attaching steering assembly to front suspension
crossmember. Then remove the steering gear assem-
bly from the front suspension crossmember.

Fig. 12 Supporting Front Suspension Crossmember

but do not remove rear bolts from crossmem-
ber.

Fig. 15 Steering Gear Assembly Mounting Bolts

(15) Transfer required parts from removed steering
gear assembly to the replacement steering gear, if a
new steering gear is being installed.

INSTALL
(1) Install steering gear assembly on front suspen-
sion crossmember. Install the 4 steering gear assem-
Fig. 13 Front Suspension Crossmember Mounting bly to front crossmember mounting bolts (Fig. 15).
Bolts
PL STEERING 19 - 31
REMOVAL AND INSTALLATION (Continued)
Torque the 4 steering gear mounting bolts to 68 N·m (5) If vehicle is equipped with power steering,
(50 ft. lbs.). install power steering pressure and return hose rout-
(2) Using the transmission jack, raise front sus- ing bracket and attaching screw on front suspension
pension crossmember and steering gear against body crossmember (Fig. 9). Torque hose routing bracket to
and frame rails of vehicle. Start the 2 rear bolts into crossmember attaching bolt (Fig. 9) to 23 N·m (17 ft,
tapping plates, attaching front suspension crossmem- lbs.).
ber to body of vehicle (Fig. 13). Then install the 2 (6) If the vehicle is equipped with power steering,
front bolts, attaching front suspension crossmember install vehicle wiring harness connector onto power
to frame rails of vehicle (Fig. 13). Tighten the 4 steering fluid pressure switch on steering gear
mounting bolts, until front suspension crossmember assembly (Fig. 8). Be sure locking tab on wiring har-
is against body of vehicle at the 4 mounting points. ness connector is securely latched to pressure switch.
Then torque the 4 mounting bolts to 2 N·m (20 in. (7) Install tie rod end into the steering knuckle.
lbs.) to hold front suspension crossmember in posi- Start tie rod end to steering knuckle attaching nut
tion. onto stud of tie rod end. While holding stud of tie rod
end stationary, tighten tie rod end to steering
CAUTION: When front suspension crossmember is knuckle attaching nut (Fig. 6). Then using a crowfoot
installed back in vehicle, crossmember MUST be and 11/32 socket (Fig. 17), torque tie rod end attach-
aligned with positioning marks previously scribbed ing nut to 55 N·m (40 ft. lbs.).
into body of vehicle (Fig. 16). This MUST be done to
maintain NET BUILD front suspension alignment
settings.

(3) Using a soft face hammer, tap front suspension

crossmember into position, until it is aligned with
the 2 previously scribbed positioning marks on body
of vehicle (Fig. 16). When front suspension cross-
member is correctly positioned, torque the 2 rear
crossmember/lower control arm mounting bolts to
163 N·m (120 ft. lbs.). Then torque the 2 front cross-
member to frame rail attaching bolts to 163 N·m (120
ft. lbs.) (Fig. 13).

Fig. 17 Torquing Tie Rod End Attaching Nut

(8) Install engine/transaxle bobble strut (Fig. 5)
back on front suspension crossmember bracket.
Install and securely tighten the dampener to cross-
member attaching bolt.
(9) Install the wheel and tire assemblies back on
vehicle. Tighten the wheel nuts to 135 N·m (100 ft.
lbs.) torque.
(10) Lower vehicle.
(11) From interior of vehicle, reconnect the steer-
ing gear coupler with the steering column shaft cou-
pler. Install steering gear coupler retaining pinch bolt
Fig. 16 Crossmember Aligned With Positioning and torque to 28 N·m (250 in. lbs.). Be sure to
Marks install the upper to lower steering coupler
(4) If vehicle is equipped with power steering, retaining bolt, retention pin (Fig. 4).
install power steering fluid pressure and return
CAUTION: Do not use automatic transmission
hoses into correct fluid ports on power steering gear
fluid.
assembly (Fig. 10). Torque power steering fluid pres-
sure and return lines to steering gear tube nuts (Fig. (12) Fill power steering pump fluid reservoir to the
10) to 31 N·m (275 in. lbs.). (Full-Cold) proper level.
19 - 32 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(13) Start the engine and let run for a few seconds. the outer tie rod end. Pull the collar off the end of
Then turn the engine off. the outer tie rod.
(14) Add fluid if necessary.
(15) Raise front wheels of vehicle off the ground.
(16) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. Fill pump reservoir to correct
level with Mopart, Power Steering Fluid, or
equivalent. See Checking Fluid Level.
(17) Lower front wheels of vehicle back on the
ground.

CAUTION: During this procedure do not allow the

steering gear inner tie rod boots to become twisted.
(See Wheel Alignment in the suspension section of
this service manual).

(18) Adjust the front Toe setting on the vehicle.

Refer to the Toe Setting Procedure in Front Suspen- Fig. 19 Outer Tie Rod
sion Service Procedures in this group of the service (2) Remove the nut attaching the outer tie rod end
manual. Refer to the Specifications Section at the to steering knuckle (Fig. 20). Nut is to be removed
end of this group for the desired front Toe specifica- from tie rod end using the following procedure,
tion. hold tie rod end stud with a 11/32 socket while
(19) Tighten tie rod jam nut (Fig. 18) to 61 N·m loosening and removing nut with wrench.
(45 ft.lbs.) torque.

Fig. 20 Removing /Installing Tie Rod End Attaching

Fig. 18 Outer Tie Rod End Jam Nut
Nut
(20) Adjust steering gear to tie rod boots at tie
(3) Remove tie rod end from steering knuckle
rods.
using Remover, Special Tool MB-991113 (Fig. 21) .
(4) Remove outer tie rod from inner tie rod by un-
DISASSEMBLY AND ASSEMBLY threading it from the inner tie rod.

OUTER TIE ROD ASSEMBLE

(1) Install the jam nut (Fig. 19) on inner tie rod
DISASSEMBLE end.
(1) Loosen the inner tie rod to outer tie rod jam
nut (Fig. 19). Thread the jam nut far enough up the
inner tie rod to pull the collar (Fig. 19) away from
PL STEERING 19 - 33
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 21 Tie Rod End Removal From Steering

Fig. 22 Torquing Tie Rod End Attaching Nut
Knuckle
Alignment in the suspension section of this service
NOTE: Be sure the collar is installed on the inner
manual).
tie rod with the flat end of the collar against jam nut
and the open end of the collar facing the outer tie (7) Adjust the front Toe setting on the vehicle.
rod end. Refer to the Toe Setting Procedure in Front Suspen-
sion Service Procedures in this group of the service
(2) Install the collar (Fig. 19) on the inner tie rod.
manual. Refer to the Specifications Section at the
(3) Install outer tie rod onto inner tie rod (Fig. 19).
end of this group for the desired front Toe specifica-
(4) Position the collar around the end of the outer
tion.
tie rod (Fig. 19).
(5) Thread the jam nut down the inner tie far CAUTION: Prior to tightening the jam nut to the
enough to hold the collar in place on the outer tie specified torque, check the orientation of the collar
rod. Do not tighten jam nut. to be sure it is in the proper position to fit up
(6) Install the tie rod end into the steering against the outer tie rod end.
knuckle. Start tie rod end to steering knuckle attach-
ing nut onto stud of tie rod end. While holding stud (8) Torque the tie rod jam nut (Fig. 19) to a torque
of tie rod end stationary, tighten tie rod end to steer- of 55 N·m (40 ft. lbs.) torque.
ing knuckle attaching nut (Fig. 20). Then using a (9) Adjust the steering gear to inner tie rod boots
crowfoot and 11/32 socket (Fig. 22), torque the tie rod at inner tie rod if they became twisted during Toe
end attaching nut to 61 N·m (45 ft. lbs.). adjustment.
CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
19 - 34 STEERING PL

SPECIFICATIONS SPECIAL TOOLS

STEERING GEAR FASTENER TORQUE POWER STEERING GEAR
SPECIFICATIONS

DESCRIPTION TORQUE
FRONT SUSPENSION CROSSMEMBER:
To Body Mounting Bolts . . . . . .163 N·m (120 ft. lbs.)
STEERING GEAR:
To Crossmember Mounting Bolts .68 N·m (50 ft. lbs.)
OUTER TIE ROD:
To Steering Knuckle Nut . . . . . . .55 N·m (40 ft. lbs.)
To Inner Tie Rod Jam Nut . . . . . .61 N·m (45 ft. lbs.)
POWER STEERING HOSE: Remover Tie Rod End MB–990635
Tube Nuts . . . . . . . . . . . . . . . . .31 N·m (275 in. lbs.)
Routing Bracket At Crossmember.23 N·m (17 ft. lbs.)

P/S System Analyzer 6815

PL STEERING 19 - 35

STEERING COLUMN

INDEX
page page

DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

STEERING COLUMN ASSEMBLY . . . . . . . . . . . . 35 STEERING COLUMN SERVICE
STEERING GEAR TO STEERING PROCEDURE WARNINGS . . . . . . . . . . . . . . . 37
COLUMN COUPLING . . . . . . . . . . . . . . . . . . . 36 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING SPECIFICATIONS
STEERING COLUMN TO STEERING STEERING COLUMN FASTEER
GEAR COUPLING . . . . . . . . . . . . . . . . . . . . . . 36 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 42
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 36

DESCRIPTION AND OPERATION nents of the steering column assembly, are the key
cylinder, ignition switch, multi- function switch, clock
STEERING COLUMN ASSEMBLY spring, trim shrouds and steering wheel. These
Both the standard non-tilt and tilt steering col- replaceable components of the steering column can be
umns (Fig. 1) have been designed to be serviced only serviced without requiring removal of the steering
as complete assemblies, if a component of the steer- column from the vehicle.
ing column is defective. The only replaceable compo-

Fig. 1 Non-Tilt And Tilt Steering Column Assemblies

19 - 36 STEERING PL
DESCRIPTION AND OPERATION (Continued)
STEERING GEAR TO STEERING COLUMN STEERING COUPLING INSPECTION
COUPLING PROCEDURE
This vehicle uses a corrugated design for the lower (1) Remove the pinch bolt safety pin from the
coupling used to connect the steering column to the steering column shaft coupling pinch bolt (Fig. 3).
steering gear (Fig. 2). (2) Loosen the coupling pinch bolt retaining nut
This coupling has a hollow corrugated tube (Fig. 2) and remove pinch bolt (Fig. 3) from steering coupler.
which allows the coupling to bend rather then (Pinch bolt nut is caged to coupler and is not
colapse when a vehicle is involved in a collision. removable.) Then separate the steering column
upper coupling from the lower coupling.

Fig. 2 Steering Gear To Steering Column Coupling

Fig. 3 Steering Column To Coupling Attachment
DIAGNOSIS AND TESTING
(3) Remove the silencer seal (Fig. 4) enclosing the
steering column coupling.
STEERING COLUMN
For diagnosis of conditions relating to the steering
column, refer to the steering system diagnosis charts,
in the diagnosis and testing section at the beginning
of this group.

STEERING COLUMN TO STEERING GEAR

COUPLING
STEERING COLUMN COUPLING INSPECTION
The steering column coupling MUST be inspected
whenever a vehicle is involved in an impact or when-
ever any of the following conditions exist.
(1) The steering column coupling must be
inspected whenever a vehicle is involved in a colli-
sion which deploys the air bag, regardless of the
extent of damage done to the vehicle.
(2) If a vehicle is involved in an impact of the vehi- Fig. 4 Steering Column Coupling Seal
cles front suspension or under carriage, which results (4) Inspect steering column coupling in the follow-
in any type of damage to the front suspension cross- ing areas for signs of damage:
member. • Inspect the sealing collar on the lower coupling
(3) Under any conditions which result in the steer- (Fig. 5) to ensure the it is not cracked, broken, or
ing column assembly or steering column shaft receiv- otherwise damaged requiring coupling replacement.
ing a force great enough to move the steering column • Inspect the corrugated section (Fig. 5) of the
or shaft forward or rearward in a vehicle. lower coupling for the following conditions or any
other visible signs of damage.
• Uneven spacing between the corrugations on
the coupling.
PL STEERING 19 - 37
DIAGNOSIS AND TESTING (Continued)
• Dings or dents in the corrugations of the cou- REMOVAL AND INSTALLATION
pling or anywhere else on the coupling wall.
• A bend in the corrugated section of the cou- STEERING COLUMN SERVICE PROCEDURE
pling. WARNINGS
WARNING: BEFORE BEGINNING ANY SERVICE
PROCEDURES THAT INVOLVES REMOVING THE
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,

COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
Fig. 5 Steering Column Coupling Inspection
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
If any of the preceding conditions exist the steering THE AIR BAG AND POSSIBLE PERSONAL INJURY.
coupling MUST be replaced. THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
The steering gear must be removed from the vehi- NALLY USED FOR THE AIR BAG COMPONENTS,
cle to allow access for replacement of the lower cou- HAVE SPECIAL COATINGS AND ARE SPECIFI-
pling. Refer to Steering Gear Service Procedures in CALLY DESIGNED FOR THE AIR BAG SYSTEM.
this group of the service manual for the required THEY MUST NEVER BE REPLACED WITH ANY SUB-
steering gear removal procedure. STITUTES. ANYTIME A NEW FASTENER IS
(5) If lower coupling does not require replacement, NEEDED, REPLACE WITH THE CORRECT FASTEN-
install steering column upper coupling silencer seal ERS PROVIDED IN THE SERVICE PACKAGE OR
(Fig. 4) back on the vehicle. FASTENERS LISTED IN THE PARTS BOOKS.
(6) Ensure front wheels of vehicle are positioned BEFORE SERVICING A STEERING COLUMN
straight-ahead and then align and attach steering EQUIPPED WITH AN AIR BAG, REFER TO GROUP
column upper coupling to lower coupling (Fig. 3). 8M, ELECTRICAL FOR PROPER AND SAFE SER-
Install the coupling pinch bolt (Fig. 3). Tighten the VICE PROCEDURES.
pinch bolt nut to a torque of 28 N·m (250 in. lbs.). Be
sure to install upper to lower steering coupling
pinch bolt safety pin (Fig. 3). NOTE: Safety goggles should be worn at all times
when working on steering columns.

CAUTION: Disconnect negative (ground) cable

from the battery, before servicing any column com-
ponent.

CAUTION: Do not attempt to remove the pivot pins

to disassemble the tilting mechanism. Damage will
occur.
19 - 38 STEERING PL
REMOVAL AND INSTALLATION (Continued)
STEERING COLUMN
REMOVE
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Before beginning removal of steering column
assembly from vehicle, be sure front wheels of vehicle
are in the straight ahead position.
(3) Remove the 4 screws attaching steering column
cover, to lower instrument panel. Then remove the
trim panel from the instrument panel (Fig. 6).

Fig. 8 Speed Control Switches

WARNING: WHEN AN UNDEPLOYED AIR BAG
ASSEMBLY IS TO BE REMOVED FROM THE STEER-
ING WHEEL, DISCONNECT BATTERY GROUND
CABLE AND ISOLATE. ALLOW SYSTEM CAPACI-
TOR TO DISCHARGE FOR TWO MINUTES, THEN
BEGIN AIR BAG REMOVAL.

(6) Remove the 2 fasteners, 1 on each side of steer-

ing wheel, attaching the air bag module to the steer-
ing wheel (Fig. 9).
Fig. 6 Steering Column Cover
(4) Remove 3 screws (Fig. 7) attaching the steering
column cover liner to the instrument panel. Remove
the liner from the lower instrument panel.

Fig. 9 Air Bag Module Mounting Bolts

Fig. 7 Steering Column Cover Liner

(5) If vehicle is equipped with speed control,
remove the speed control switches from the steering
wheel (Fig. 8). If vehicle is not equipped with speed
control, remove the trim covers from the sides of the
steering wheel.
PL STEERING 19 - 39
REMOVAL AND INSTALLATION (Continued)
WARNING: WHEN HANDLING AN UNDEPLOYED
AIR BAG MODULE DURING SERVICING OF THE
STEERING COLUMN THE FOLLOWING PRECAU-
TIONS SHOULD BE OBSERVED. AT NO TIME
SHOULD ANY SOURCE OF ELECTRICITY BE PER-
MITTED NEAR THE INFLATOR ON THE BACK OF
THE AIR BAG MODULE. WHEN CARRYING A LIVE
MODULE, THE TRIM COVER SHOULD BE POINTED
AWAY FROM THE BODY TO MINIMIZE INJURY IF
MODULE ACCIDENTLY DEPLOYS. IF AIR BAG MOD-
ULE IS PLACED ON A BENCH OR OTHER SUR-
FACE, PLASTIC COVER SHOULD BE FACE UP TO
MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL
DEPLOYMENT.

(7) Remove air bag module from center of steering

wheel. Then disconnect the clock spring electrical Fig. 11 Clock Spring To Horn Switch Wiring
lead from the back of the air bag module (Fig. 10). Connection

Fig. 10 Air Bag Module Electrical Connection Fig. 12 Steering Wheel Attaching Nut
(8) Disconnect the wiring lead for the horn switch
in the airbag module from the wiring lead coming
from the clockspring (Fig. 11).
(9) Turn the lock cylinder to the off position and
remove the key from the lock cylinder
(10) Turn the steering wheel to the left 1/2 a turn
(180°) until the steering column lock is engaged (Fig.
12).
(11) Remove the steering wheel retaining nut,
from the steering column shaft (Fig. 12). If equipped,
remove the damper weight from the steering wheel.

CAUTION: When installing wheel puller on the

steering wheel be sure puller bolts are fully seated
in the threaded holes on the steering wheel. If bolts
are not fully seated in the threaded holes, the
threads may be stripped out of the steering wheel Fig. 13 Steering Wheel Puller Installed
when removing the steering wheel.
CAUTION: Do not bump or hammer on steering
(12) Install Puller, Snap-On CJ2001P or an equiv- wheel or steering column shaft when removing
alent on the steering wheel (Fig. 13). steering wheel from steering column.
19 - 40 STEERING PL
REMOVAL AND INSTALLATION (Continued)
(13) Remove steering wheel assembly from steer- caged to coupler and is not removable.) Then
ing column shaft using Puller, Special Tool C-3428-B separate steering column shaft coupling from lower
or equivalent. steering coupling.
(14) Remove key lock cylinder from steering col-
umn. Key lock cylinder is removed from steering col-
umn using the following procedure. Place the key
lock cylinder in the Run position. Then through the
hole in lower shroud, (Fig. 14) depress lock cylinder
retaining tab and remove key lock cylinder.

Fig. 16 Upper To Lower Steering Column Coupler

Disassembly
(18) Remove the 2 nuts attaching the lower
mounting bracket of the steering column to the steer-
ing column mounting bracket.
(19) Remove the 2 nuts mounting the steering col-
Fig. 14 Key Lock Cylinder Access Hole In Steering umn upper bracket to the steering column support
Column Shrouds bracket (Fig. 17).
(15) Remove the 3 screws attaching the upper and
lower shroud to the steering column (Fig. 15). First
remove lower shroud from steering column, then
release tilt lever and tilt steering column to its low-
est point. Then remove upper shroud from steering
column.

Fig. 17 Steering Column Upper Support Bracket

Attaching Nuts
(20) Lower steering column in the steering column
access opening of the lower instrument panel.
(21) Remove routing clip (Fig. 18) holding wiring
harness to jacket of steering column. Then remove
Fig. 15 Upper And Lower Steering Column Shrouds wiring harness connectors from the multi- function
(16) Remove retaining pin from pinch bolt in steer- switch and the windshield wiper switch (Fig. 18).
ing column upper coupling (Fig. 16). (22) Remove the vehicle wiring harness connec-
(17) Loosen the steering column upper coupling tors from the ignition switch and clock spring (Fig.
pinch bolt retaining nut and remove pinch bolt (Fig. 19).
16) from steering coupling. (Pinch bolt nut is
PL STEERING 19 - 41
REMOVAL AND INSTALLATION (Continued)
attaching nuts (Fig. 17). Do not tighten the 2
mounting nuts at this time.
(5) Install and securely tighten the 2 nuts mount-
ing the steering column lower mounting bracket to
the steering column support bracket.
(6) Install the upper and lower steering column
shrouds onto the lock housing of the steering column
assembly. Install and securely tighten the 3 upper to
lower steering column shroud to lock housing attach-
ing screws (Fig. 15).
(7) Be sure both breakaway capsules are still fully
seated in the slots of the upper steering column
mounting bracket. Equally tighten both steering col-
umn mounting nuts, until upper steering column
mounting bracket is seated against support bracket.
Then tighten the 2 steering column upper mounting
Fig. 18 Steering Column Wiring Connections bracket nuts to a torque of 17 N·m (150 in. lbs.).
(8) Tighten the steering column lower mounting
bracket nuts (2) to a torque of 17 N·m (150 in. lbs.).
(9) Assemble the steering column flex coupler to
the intermediate steering coupler (Fig. 16). Install
the steering coupler pinch bolt. Torque the pinch bolt
nut to 28 N·m (250 in. lbs.). Be sure to install
upper to lower steering coupler pinch bolt
retaining pin (Fig. 16).
(10) Install the lower instrument panel steering
column cover liner onto lower instrument panel.
Install and securely tighten the 3 liner to instrument
panel attaching screws (Fig. 7).
(11) Install lower instrument panel steering col-
umn cover (Fig. 6) on lower instrument panel. Install
and securely tighten the 4 screws (Fig. 6) attaching
steering column cover, to lower instrument panel.

Fig. 19 Steering Column Wiring Connections CAUTION: Clock spring centering procedure MUST
be performed prior to installing steering wheel
(23) Remove steering column from vehicle through assembly. If clock spring is not centered it may be
the drivers door of the passenger compartment. Use overextended, causing clock spring assembly to
care to avoid damaging the paint or interior trim. become inoperative.
INSTALL (12) Center the clock spring using the following
(1) Install steering column into steering column procedure.
access opening in lower instrument panel. • Depress the 2 plastic locking pins to disengage
(2) Install the vehicle wiring harness connectors, clockspring locking mechanism.
into the ignition switch and clock spring assembly • Keeping locking mechanism disengaged, rotate
(Fig. 19). the clockspring rotor in the CLOCKWISE DIREC-
(3) Install vehicle wiring harness connectors into TION to the end of the travel. Do not apply excessive
multi-function switch and turn signal switch (Fig. 18) torque.
on steering column assembly. Install routing clip • From the end of travel, rotate the rotor 2 full
(Fig. 18) holding wiring harness to jacket of steering turns and an additional half turn in the counter-
column. clockwise direction. (The horn wire should end up at
(4) Install the studs in the steering column sup- the top and the squib wire at the bottom.) Engage
port bracket, into the slots in the aluminum capsules the clockspring locking mechanism.
in the upper mounting bracket of the steering column
(Fig. 17). Partially install the 2 upper steering col-
umn assembly mounting bracket to support bracket
19 - 42 STEERING PL
REMOVAL AND INSTALLATION (Continued)
CAUTION: Do not install steering wheel onto shaft bolts (Fig. 9). Torque the 2 air bag module attaching
of steering column assembly by driving it onto the bolts to 10 N·m (90 in. lbs.).
shaft. Pull steering wheel down onto steering col- (18) Install key lock cylinder into lock housing.
umn shaft using ONLY the steering wheel retaining Key lock cylinder is installed by positioning key cyl-
nut. inder in the run position so retaining tab can be
depressed and the pushing key cylinder into lock hos-
(13) Feed clock spring wiring leads through hole in ing until retaining tab locks into key lock cylinder.
steering wheel (Fig. 20). Position steering wheel on (19) Reconnect ground cable to Negative post of
shaft of steering column assembly, making sure to fit the battery. When reconnecting battery on a
flats on hub of steering wheel with formations on vehicle that has had the air bag module
inside of clockspring. removed, the following procedure should be
used.
• Remove forward console or cover as necessary.
• Connect DRB II to ASDM diagnostic 6-way con-
nector, located at right side of the ASDM module.
• Turn ignition key to ON position. Exit vehicle
with the DRB II. Install the latest version of the
proper diagnostic cartridge into the DRB II.
• Ensuring that their are no occupants in the
vehicle, connect negative cable to negative post of the
battery.
• Using the DRB II read and record active fault
codes. Also read and record any stored fault codes.
Refer to the Passive Restraint Diagnostic Test Man-
ual if any faults are found.
• Erase stored faults if there are no active fault
codes. If problems remain, fault codes will not erase.
• From the passenger side of the vehicle, turn
Fig. 20 Steering Wheel Installation
ignition key to OFF and then ON observing instru-
(14) Install steering wheel to steering column ment cluster air bag lamp. It should go on for six to
shaft retaining nut and tighten until steering wheel eight seconds, then go out. This will indicate that the
is fully installed on shaft. The tighten steering wheel air bag system is functioning normally.
retaining nut to a torque of 61 N·m (45 ft. lbs.). (20) If air bag warning lamp fails to light,
(15) Connect the clockspring electrical leads to blinks on and off or goes on and stays on, there
components such as horn switches and speed control is an air bag system malfunction. Refer to the
switches located in the steering wheel (Fig. 11). Passive Restraint Diagnostic Test Manual to diag-
(16) Install air bag electrical lead from clock nose the system malfunction.
spring, into connector on back of air bag module (Fig. (21) Test the operation of the horn, lights and any
10). Be sure electrical connector from clock- other functions that are steering column operated. If
spring is securely latched into air bag module applicable reset the radio and the clock.
connector. (22) Road test vehicle to ensure proper operation
of the steering system and the speed control system.
CAUTION: The fasteners, screws, and bolts, origi-
nally used for the air bag components are specifi-
cally designed for the air bag system. They must SPECIFICATIONS
never be replaced with any substitutes. Anytime a
new fastener is needed, replace only with correct STEERING COLUMN FASTENER TORQUE
fasteners provided in service packages or fasteners SPECIFICATIONS
listed in the parts book.
DESCRIPTION TORQUE
(17) Install air bag module into center of steering Steering Wheel
wheel. Align air bag module mounting holes with bolt
Retaining Nut . . . . . . . . . . . . . . .61 N·m (45 ft. lbs.)
holes in steering wheel. Install only the 2 original
Steering Column Assembly
or correct replacement air bag module attaching
Upper And Lower Mounting Bracket
Attaching Nuts . . . . . . . . . . .17 N·m (150 in. lbs.)