AutoZone 2002 Chevrolet Malibu 3.1L SFI OHV 6cyl | Repair Guides | Steering & Suspension | Steering | Power Steering Gear | AutoZone.com

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    2002 Chevrolet Malibu 3.1L SFI OHV 6cyl

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    405 N COLLEGE ST
    (479) 443-4043

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    PT Cruiser, 2001 - 2005

    Power Steering Gear

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    Removal & Installation



    1. Place the steering wheel in the straight ahead position. Using a steering wheel holder, lock the steering wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation.
    2.  
    3. Remove the silencer pad below the knee blocker panel below the steering column.
    4.  
    5. Fold down and remove the knee blocker.
    6.  
    7. Remove the steering column coupling retainer pin, back off the pinch bolt nut, and remove the steering column coupling pinch bolt (the pinch bolt nut is caged to the coupling and is not removable). Separate the upper and lower steering column couplings.
    8.  
    9. Raise the vehicle.
    10.  
    11. Remove both front tire and wheel assemblies from the vehicle.
    12.  
    13. Remove nuts attaching both outer tie rods to the steering knuckles. Remove each nut by holding the tie rod stud stationary while loosening and removing the nut with a crowfoot wrench (or open-end wrench).
    14.  
    15. Remove the outer tie rods from the steering knuckles using Remover, Special Tool MB991113.
    16.  
    17. Remove the tie rod heat shields.
    18.  
    19. On vehicles equipped with a power steering fluid pressure switch, release the locking tab on the wiring harness connector for the power steering fluid pressure switch, then remove the wiring harness connector from the power steering fluid pressure switch.
    20.  
    21. Back out the tube nut securing the power steering fluid pressure hose to the gear.
    22.  
    23. Disconnect the cooler or return hose at the power steering gear outlet port fitting.
    24.  
    25. On vehicles equipped with crossmember mounted power steering fluid coolers:

      Remove the cooler tube from the right routing clip.
       
      Remove the two screws securing the cooler to the front suspension crossmember.
       

    26.  
    27. Allow the cooler to hang out of the way.
    28.  
    29. Remove the pencil strut from the right front corner of the crossmember and body of the vehicle. Remove the washer behind the strut from the torque strut bolt.
    30.  
    31. Remove the screws fastening the front fascia to the reinforcement as necessary in order to access the drive belt splash shield forward fastener screw.
    32.  
    33. Remove the drive belt splash shield fasteners. Remove the shield.
    34.  
    35. Remove the bolt mounting the engine torque strut to the right forward corner of the front suspension crossmember.
      NOTE
      Before removing the front suspension crossmember from the vehicle, the location of the crossmember must be scribed on the body of the vehicle. Do this so the crossmember can be relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If the front suspension crossmember is not reinstalled in exactly the same location as before removal, the preset front wheel alignment settings (caster and camber) will be lost.

    36.  
    37. Using an awl, scribe a line marking the location of where the front suspension crossmember is mounted against the body of the vehicle.

      Click image to see an enlarged view

      Fig. Marking the location of the crossmember as it is mounted against the body of the vehicle

    38.  
    39. Position a transmission jack under the center of the front suspension crossmember and raise it to support the bottom of the crossmember.
    40.  
    41. Loosen all six bolts attaching the front suspension crossmember to the frame rails of vehicle. Do not completely remove the two mounting bolts going through the lower control arm rear isolator bushings. They are designed to disengage from the body threads yet stay within the lower control arm rear isolator bushing. Back the two bolts out just enough to disengage the threaded tapping plates in the body of the vehicle. Completely remove the other four bolts.
    42.  
    43. Lower the front suspension crossmember using the transmission jack enough to allow the power steering gear to be removed from the rear of the crossmember. When lowering front suspension crossmember, do not let crossmember hang from lower control arms. The weight should be supported by the transmission jack.
    44.  
    45. Remove the roll pin securing the steering column lower coupling to the power steering gear pinion shaft using a roll pin punch. Push the steering column lower coupling up and off of the power steering gear pinion shaft.
    46.  
    47. Release the pinion shaft dash cover seal from the tabs cast into the power steering gear housing and remove the seal from the power steering gear.
    48.  
    49. Loosen and remove the four bolts attaching the power steering gear to the front suspension crossmember . Remove the power steering gear from the front suspension crossmember.

      Click image to see an enlarged view

      Fig. The power steering gear assembly



      Click image to see an enlarged view

      Fig. View of the power steering gear and crossmember

    50.  

    To install:

    Click image to see an enlarged view

    Fig. Power steering pressure switch

    1. Install the steering gear on the front suspension crossmember. Install the four power steering gear mounting bolts. Tighten the mounting bolts to a torque of 45 ft. lbs. (61 Nm).
    2.  
    3. Install the pinion shaft dash cover seal over the power steering pinion shaft and onto the power steering gear housing. Align the holes on each side of the seal with the tabs cast into the power steering gear housing.
    4.  
    5. With the steering column lower coupling pushed partway up through its hole in the dash panel, match the flat on the inside of the steering column lower coupling to the flat on the power steering gear pinion shaft and slide the coupling onto the top of the pinion shaft. Align the roll pin hole in the coupling with the groove in the pinion shaft and install the roll pin through the coupling until it is centered.
    6.  
    7. Center the power steering gear rack in its travel.
    8.  
    9. Using the transmission jack, raise the front suspension crossmember and power steering gear until the crossmember contacts its mounting spot against the body and frame rails of the vehicle. As the crossmember is raised, carefully guide the steering column lower coupling up through its hole in the dash panel.
    10.  
    11. Start the two crossmember mounting bolts through the lower control arm rear isolator bushings into the tapping plates mounted in the body. Next, install the two front and the two rear mounting bolts attaching front suspension crossmember to frame rails of vehicle. Lightly tighten all six mounting bolts to approximately 20 inch lbs. (2 Nm) to hold the front suspension crossmember in position at this time.
      NOTE
      When reinstalling the front suspension crossmember back in the vehicle, it is very important that the crossmember be attached to the body in exactly the same spot as when it was removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost.

    12.  
    13. Using a soft face hammer, tap the front suspension crossmember back-and-forth or side-to-side until it is aligned with the previously scribed positioning marks on the body of the vehicle. Once the front suspension crossmember is correctly positioned, tighten the two crossmember mounting bolts through the lower control arm rear isolator bushings to a torque of 185 ft. lbs. (250 Nm), then tighten the four remaining crossmember mounting bolts to a torque of 113 ft. lbs. (153 Nm).
    14.  
    15. Fasten the engine torque strut to the right forward corner of the front suspension crossmember using its mounting bolt.
    16.  
    17. Install the washer on the end of the stud extending from the torque strut bolt.
    18.  
    19. Install the pencil strut to the right front corner of the crossmember and body of the vehicle). Tighten the pencil strut nuts to a torque of 38 ft. lbs. (52 Nm).
    20.  
    21. Install the drive belt splash shield and fasteners.
    22.  
    23. Install the screws fastening the front fascia to the reinforcement.
    24.  
    25. Using a lint free towel, wipe clean the open power steering hose ends and the power steering gear ports. Replace the pressure hose used O-ring with new. Lubricate the O-ring with power steering fluid.
    26.  
    27. On vehicles equipped with crossmember mounted power steering fluid coolers:

      Place the cooler in mounting position and snap the cooler tube going to the gear into the right routing clip on the front of the gear. Close the routing clip.
       
      Install the two screws securing the cooler to the front suspension crossmember.
       

    28.  
    29. Tighten the screws to a torque of 90 inch lbs. (10 Nm).
    30.  
    31. Slide the cooler or return hose onto the steel gear outlet port fitting. Secure the clamp on the hose past the bead on the steel fitting.
      CAUTION
      On vehicles equipped with crossmember mounted power steering fluid coolers, forward of the steering gear, the power steering fluid pressure hose routes between the front suspension crossmember and the driveshaft. When tightening the pressure hose tube nut to the steering gear, the pressure hose must be positioned (clocked) such that its final routing (after tightened to 23 ft. lbs. (31 Nm) offers 4-10 mm clearance to the front suspension crossmember (measured at the pressure hose steel-to-rubber coupling). There should be a clocking donut on the hose to preset this distance.

    32.  
    33. Attach the power steering fluid pressure hose to its port on the power steering gear.
    34.  
    35. On turbocharged vehicles, install routing clip up from gear outlet tube onto fluid pressure hose tube.
    36.  
    37. While making sure the pressure hose is not in contact with any vehicle components (see preceding caution), tighten the pressure hose tube nut at the gear to 23 ft. lbs. (31 Nm).
    38.  
    39. On vehicles equipped with a power steering fluid pressure switch, reconnect the wiring harness connector at the power steering fluid pressure switch. Be sure the locking tab on the wiring harness connector is securely latched.
    40.  
    41. Perform the following to each outer tie rod:

      Place the tie rod heat shield on the knuckle's steering arm, aligning the hole in the shield with the hole in the knuckle and the tangs on the outside of the shield with the outside configuration of the steering arm. The shield should now be facing outboard, away from the power steering gear and tie rod.
       
      Attach the outer tie rod end to its steering knuckle.
       
      Start the attaching nut onto the stud of the outer tie rod.
       
      While holding the stud of the tie rod stationary with a wrench, tighten the attaching nut.
       
      Using a crowfoot wrench attached to a torque wrench, tighten the attaching nut to 40 ft. lbs. (54 Nm).
       

    42.  
    43. Install the tire and wheel assemblies back on vehicle. Tighten the wheel mounting nuts to 100 ft. lbs. (135 Nm).
    44.  
    45. Lower the vehicle to ground level.
    46.  
    47. Install the dash-to-lower coupling seal in place over the lower coupling's plastic collar.
      NOTE
      Verify that grease is present on the lip of the dash-to-coupling seal where it contacts the coupling's plastic collar.

    48.  
    49. Inside the passenger compartment, reconnect the steering column lower coupling to the steering column upper coupling. Install the coupling pinch bolt and tighten the pinch bolt nut to a torque of 250 inch lbs. (28 Nm). Install the pinch bolt retainer pin.
    50.  
    51. Remove the steering wheel holder.
    52.  
    53. While looking under the instrument panel at the lower coupling, rotate the steering wheel back-and-forth to verify that the lower coupling does not squeak against the dash-to-coupling seal.
    54.  
    55. Install the knee blocker.
    56.  
    57. Install the silencer pad below the knee blocker panel below the steering column.
    58.  
    59. Perform the Power Steering Pump Initial Operation service procedure to properly fill and bleed the power steering system.
    60.  
    61. Check for fluid leaks.
    62.  
    63. Adjust the front toe setting on the vehicle.
    64.  

     
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