GM Astro/Safari 1985-1996 Repair Guide

Power Steering Pump

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7



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Fig. Fig. 1: Exploded view of the power steering pump assembly mounting-2.5L engine



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Fig. Fig. 2: Exploded view of the power steering pump assembly mounting-early-model 4.3L engine



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Fig. Fig. 3: Removing the power steering pump pulley-1985-92 vehicles



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Fig. Fig. 4: Installing the power steering pump pulley



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Fig. Fig. 5: Pump pulley removal and installation-1993-96 vehicles



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Fig. Fig. 6: Exploded view of the power steering pump mounting-late-model 4.3L engines (1993-96 shown)



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Fig. Fig. 7: Typical power steering pump hose routing-1996 shown

The following procedure requires the use of the GM Puller tool No. J-29785-A (1985-92), Puller J-25034-B (1993-96) or equivalent, and the GM Pulley Installer tool No. J-25033-B or equivalent.

  1. Disconnect the negative battery cable for safety.
  2.  
  3. For 1996 vehicles, remove the air cleaner assembly for access.
  4.  
  5. For 1993-96 vehicles, remove the hood latch and the upper fan shroud.
  6.  
  7. Release tension and remove the drive belt. For details, please refer to General Information & Maintenance of this information.
  8.  
  9. Remove the power steering pump pulley using a suitable puller tool.
  10.  
  11. Remove the power steering pump retaining bolts, then reposition the pump as necessary for access to the hoses.
  12.  
  13. Position a fluid catch pan under the power steering pump.
  14.  
  15. Remove the hoses from the power steering pump and drain the excess fluid into the catch pan.
  16.  


WARNING
Be sure to cap all openings in the pump hydraulic system to prevent excessive fluid spillage and the possibility of system contamination.

  1. Remove the power steering pump from the vehicle.
  2.  

To install:
  1. Position the pump to the vehicle, then uncap and connect the pump hoses.
  2.  
  3. Install the steering pump to the retaining bracket, then secure using the retaining bolts. Tighten the power steering pump-to-bracket bolts to 37 ft. lbs. (50 Nm). For 1996 vehicles, tighten the nut to 30 ft. lbs. (41 Nm).
  4.  

On early-model vehicles where the drive belt is tensioned by pivoting the power steering pump assembly, do NOT fully tighten the mounting bolts at this time, since you will just have to loosen them again for belt installation and adjustment.

  1. Install the pump pulley using the GM Pulley Installer tool No. J-25033-B or equivalent. Press the drive pulley onto the power steering pump.
  2.  
  3. Hand-tighten the pivot bolt, the adjusting bolt and the washer.
  4.  
  5. Install the drive belt. On early-model vehicles so equipped, properly adjust the belt tension. For details on belt installation and tension adjustment, please refer to General Information & Maintenance of this information.
  6.  
  7. For 1993-96 vehicles install the upper fan shroud and the hood latch assembly.
  8.  
  9. For 1996 vehicles, install the air cleaner assembly.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Refill the power steering reservoir and bleed the power steering system.
  14.  
  15. Remove the jackstands and carefully lower the vehicle.
  16.  
  17. Road test the vehicle, then check and top-off the power steering fluid.
  18.  

SYSTEM BLEEDING



The power steering system should be bled after any component has been replaced, after any fluid line has been disconnected or air is suspected as the cause of a noise in the system. The system must be properly bled to help prevent possible pump damage, and to ensure proper, trouble and noise-free operation.

Bleeding will take significantly longer on a system that has been completely emptied and/or on systems that contain long fluid lines and multiple components (such as a fluid cooler in addition to the pump, gear and reservoir).

  1. Begin the bleeding procedure with the engine and fluid COLD.
  2.  
  3. FIRMLY set the parking brake and block the rear wheels.
  4.  
  5. Raise and support the front of the vehicle safely using jackstands.
  6.  
  7. Turn the steering wheel to the full left position, then check and top off the fluid reservoir to the FULL COLD mark.
  8.  
  9. Turn the steering wheel from lock-to-lock at least 20 times, while an assistant checks the fluid level and condition in the reservoir. Add fluid as necessary to keep the level at or near the FULL COLD mark.
  10.  

Remember that if only the front wheels are raised, the fluid level on the dipstick will not be completely accurate. Keep the level a little below the mark, until the vehicle is lowered, then check and top it off as necessary.

  1. Remove the jackstands and carefully lower the vehicle. If not done earlier, install the filler cap to the reservoir.
  2.  
  3. Start the engine and allow it to idle. Run the engine for approximately 2 minutes in order to allow the fluid to warm-up.
  4.  
  5. With the engine idling, turn the wheels in both directions (to the stops) several times.
  6.  
  7. Stop the engine, then check the fluid level and condition. Add power steering fluid to the level indicated on the reservoir.
  8.  

Fluid with air in it will have a light tan or milky appearance. This air must be eliminated from the fluid before normal steering action can be obtained.

  1. Road test the vehicle to make sure the steering functions normally and is free from noise.
  2.  
  3. Allow the vehicle to stand for 2-3 hours, then recheck the power steering fluid.
  4.  

 
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