ION, L-Series, S-Series 1999-2005

Removal & Installation

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  1. Remove the air cleaner assembly.

    Click image to see an enlarged view

    Fig. Remove the pulley from the power steering pump

  2.  
  3. Remove the pulley from the power steering pump.

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    Fig. Disconnect the power steering pressure hose from the power steering pump

  4.  
  5. Disconnect the power steering pressure hose from the power steering pump.
  6.  
  7. Disconnect the power steering return hose from the power steering pump.
  8.  
  9. Remove the power steering pump to bracket bolts.

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    Fig. Remove the power steering pump from the vehicle

  10.  
  11. Remove the power steering pump from the vehicle.
  12.  
  13. Using the special tool SA9162C-2, remove the power steering pulley hub from the power steering pump.
  14.  

To install:

  1. Using the special tool SA9218NE, install the power steering pulley hub to the power steering pump.
  2.  
  3. Install the power steering pump to the power steering pump bracket, and tighten the pump to bracket bolts to 15 ft. lbs. (20 Nm).
    NOTE
    Inspect the power steering hose O-ring and replace if necessary.

  4.  
  5. Connect the power steering pressure hose to the power steering pump, and tighten the fitting to 20 ft. lbs. (27 Nm).
  6.  
  7. Connect the power steering return hose to the power steering pump, and tighten the clamp to 22 inch lbs.(2.5 Nm).
  8.  
  9. Install the Power steering pump pulley.
  10.  
  11. Install the air cleaner assembly.
  12.  
  13. Fill the power steering reservoir and bleed air from the system.
  14.  

  1. Disconnect negative battery cable.
  2.  
  3. Remove power steering pump reservoir fill cap.
    CAUTION
    Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  4.  
  5. Raise vehicle on hoist.
  6.  
  7. Place approved drain container under power steering hoses at steering gear.
  8.  
  9. Disconnect power steering hoses from the steering gear.
    NOTE
    After removing power steering hoses from gear, do not rotate steering wheel since fluid will be forced out of gear.

  10.  
  11. Remove power steering hoses from steering gear and allow system to drain.
  12.  
  13. Use a box end wrench to relieve spring tension from accessory drive belt tensioner; remove belt from power steering pump pulley.

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    Fig. On vehicles equipped with variable assist, disconnect EVO electrical connector

  14.  
  15. On vehicles equipped with variable assist, disconnect EVO electrical connector.
    NOTE
    It is not necessary to remove the three power steering pump bracket to engine block bolts.

  16.  
  17. On DOHC engine, loosen upper power steering pump bracket bolt at cylinder head.
  18.  
  19. Remove upper power steering pump bracket bolt at power steering pump.
  20.  
  21. Swing bracket aside.

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    Fig. Remove three power steering pump-to-bracket bolts only

  22.  
  23. Remove three power steering pump-to-bracket bolts only. Obtain access to bolts by rotating power steering pump pulley.

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    Fig. Remove pump (with hoses) from vehicle

  24.  
  25. Remove pump (with hoses) from vehicle.
  26.  
  27. Remove pressure and return hoses from pump.
  28.  

To install:

  1. Inspect O-ring seals on each end of the pressure hose and on the gear end of the return hose and replace if necessary. Install pressure and return hoses onto pump.
  2.  
  3. Tighten Power Steering Hoses-to-Steering Pump 20 lbs ft (27.5 Nm).
    NOTE
    Do not tighten any of the bolts until all bolts have been started.

  4.  
  5. Position pump with hose against cylinder head and loosely install all bolts. Install the power steering pump bracket-to-cylinder head support brace bolts first on the DOHC engine.
  6.  
  7. Tighten Power Steering Pump-to-Bracket Bolt 22 lbs ft (30 Nm).
  8.  
  9. On the DOHC engine, torque the support bracket bolt to power steering pump first; then torque the upper support bracket bolt at the cylinder head. Tighten Power Steering Pump-to-Bracket Bolt 22 lbs ft (30 Nm).
  10.  
  11. On vehicles equipped with variable assist, connect the EVO electrical connector.
    CAUTION
    Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  12.  
  13. Raise vehicle on hoist.
  14.  
  15. Install pressure and return hoses into steering gear, and tighten Power Steering Hoses-to-Steering Gear 20 lbs ft (27.5 Nm).
  16.  
  17. Route hoses into the steering gear hose retaining clip, return hose first, pressure hose next. Secure hose in clip.
  18.  
  19. Lower vehicle from hoist.
    NOTE
    Never overfill the power steering pump reservoir. Overfilling may cause contamination to accessory drive belt, generator, etc., resulting in premature failure.

  20.  
  21. Fill power steering pump fluid reservoir with clean power steering fluid. Install reservoir fill cap.
  22.  
  23. Install the accessory drive belt.
  24.  
  25. Bleed power steering system.
  26.  

 
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