Chevrolet Automobile Parts 2001 User's Manual
Contents
1. Retaining Ring Press Press Bearing To Shoulder Drive Shaft Of Drive Shaft Or Clearance Measured Prior To Removing ane Old Bearing f Ball Bearing support yd On Inner Race INSTALLING BEARING Note Position Of Large Lug lo Be Sure Beveled Side Of Ring Is Properly Located OX L INSTALLING RETAINING RING G90A09996 Fig 7 Installing Bearing Retaining Ring TC Series Courtesy of General Motors Corp RACK amp PINION NOTE Perform overhaul procedures with rack and pinion assembly removed from vehicle See RACK amp PINION ASSEMBLY under REMOVAL amp INSTALLATION Disassembly Pinion amp Valve Assembly CAUTION Do not hammer end of stub shaft as drive pin on pinion and valve assembly will loosen or break 1 Remove adjuster plug lock nut adjuster plug adjuster Spring and rack bearing See Fig 1 Remove retaining ring from stub shaft Remove dust cover from bottom of pinion and valve assembly housing While holding stub shaft stationary with 14 mm wrench remove lock nut from bottom of shaft 2 Center rack in housing For reassembly reference mark location of stub shaft notch on housing and measure distance between ends of tie rod boot See Fig 8 3 Using an arbor press press threaded end of pinion and valve assembly until assembly is loosened but DO NOT remove Mark second location of stub shaft notch on housing for reassembly reference 4 Remove stub shaft dust seal stub shaft sea2. 5 Remove 0 ring flow control valve assembly and flow control spring 3 Insert small punch in access hole and remove thrust plate retaining ring Using a press and 5 8 piece of bar stock press against pressure plate hub until thrust plate is removed Remove Oo ring pump ring pump rotor vanes and 2 dowel pins 4 Remove pressure plate using press if necessary Remove O ring from pressure plate Remove dowel pin from housing Remove O ring from sleeve Working from pulley side of housing drive out Sleeve with a punch Inspection Clean all parts in power steering fluid Inspect pressure plate vanes pump ring drive shaft and bearing for scoring pitting or chatter marks Replace worn or damaged parts Reassembly 1 Press new sleeve assembly into housing Install new lubricated O ring into groove in sleeve Install dowel pin into housing Install pressure plate spring Install new lubricated Oo ring into groove in pressure plate 2 Mark spot on top of pressure plate directly over dowel pin hole in plate to help align hole with dowel pin Install pressure plate into housing ensuring pin engages hole in pressure plate Install 2 pump ring dowel pins 3 Install pump rotor with counterbore larger diameter of center bore facing pulley end of housing Insert pump vanes into rotor slots With identification marks on pump ring facing upward install pump ring over dowel pins Install new lubricated O ring into housi
3. bar from crossmember Disconnect brake pipe from crossmember fastener clips Remove rack and pinion mounting bolts and nuts Using hand tools only LOOSEN DO NOT remove four crossmember mounting nuts Remove power rack and pinion through left wheelwell opening by rotating Installation To install reverse removal procedure Tighten nuts and bolts to specification See TORQUE SPECIFICATIONS Fill and bleed hydraulic System See HYDRAULIC SYSTEM BLEEDING under lubrication Adjust toe in as necessary See appropriate SPECIFICATIONS amp PROCEDURES article in WHEEL ALIGNMENT 395 13416 Fig 3 Mounting Bolt Tightening Sequence Courtesy of General Motors Corp OVERHAUL POWER STEERING PUMP CB SERIES NOTE Pump is not serviceable on Seville Disassembly 1 Remove hydraulic union fitting or VES actuator from pump See Fig 4 Remove O ring flow control valve assembly and flow control spring Insert punch in access hole and remove end cover retaining ring Press gently on pulley end of shaft to remove end cover O ring pressure plate spring and pressure plate 2 Remove shaft subassembly consisting of remaining components Disassemble subassembly noting component location for reassembly reference Cut shaft seal with a small chisel Remove and discard shaft seal Inspection Inspect pump ring rotor vanes thrust plate pressure plate and shaft for scoring pitting or chatter marks Replace worn or damaged parts R
4. in pump If flow rate does not drop one gallon 3 8L per minute go to next step 3 Increase engine speed to 1500 RPM and record flow rate Subtract flow rate from that measured in step 1 If difference between flow rates is more than one gallon 3 8L per minute remove and clean flow control valve If not go to next step 4 Turn steering wheel from stop to stop Flow rate should be less than one gallon 3 8L per minute at each stop If flow rate is not as specified check rack and pinion assembly for leakage 5 Turn engine off Remove tester Reconnect high pressure hose to pump Check fluid level Bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION REMOVAL amp INSTALLATION CAUTION When battery is disconnected vehicle computer and memory Systems may lose memory data Driveability problems may exist until computer systems have completed a relearn cycle See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery OUTER TIE ROD Removal Raise and support vehicle Remove cotter pin and castle nut from outer tie rod end Loosen outer to inner tie rod lock nut Using Steering Linkage Puller J 24319 01 separate outer tie rod end from Steering knuckle Remove outer tie rod end from inner tie rod noting number of turns required to remove Installation Install outer tie rod end with same number of turns as when removed Tighten outer to inner tie rod lock nut to specificati
5. off Turn wheels from side to side several times but DO NOT touch steering stops Add fluid if necessary to maintain level at FULL COLD mark 2 Start engine With engine idling recheck fluid level Add fluid if necessary to bring level to FULL COLD mark Install cap Return wheels to center position Lower vehicle Continue to run engine for 2 3 minutes Road test vehicle Check for leaks Ensure fluid level is at FULL HOT mark when fluid stabilizes at operating temperature ADJUSTMENTS POWER STEERING PUMP BELT SERPENTINE BELT 1 On most applications serpentine belt tension is maintained by automatic tensioner and no adjustment is necessary Ensure tensioner indicator mark on movable portion of tensioner is within limits of slotted area on stationary portion of tensioner Any reading outside these limits indicates a worn belt or defective tensioner 2 If installing NEW belt ensure tensioner indicator is within limit marks If installing original belt ensure belt operating length and or tensioner operating range marks are not out of limits Replace belt or tensioner as necessary See appropriate SERVICE ADJUSTMENT SPECIFICATIONS article in ENGINE PERFORMANCE RACK BEARING PRELOAD 1 Raise and support vehicle Turn front wheels to straight ahead position Loosen adjuster plug lock nut See Fig 1 Turn adjuster plug clockwise until it bottoms in housing Back off adjuster plug 50 70 degrees about one flat 2 While ho
6. Application Ft Lbs N m Adjuster Plug Lock Nut Magna Seek ui Queer A a Sha uin we ees Ee ee bees we d as 50 68 Ouret Valve tan e a o a ele 55 9 Crossmember Bolts IU go TE BOATES xe qunm qua A tan ten nal ay etes ae casu e e veut tree al as 81 110 Engine Frame To Body Bolts Ni IER SEEDS de BOGS iremos acie aia dris ela 2 141 191 VOD BOYA A A SEM arg dus is 1 133 180 Engine Move B olt EEN BOY S iire daaa raras ia 37 50 taner Are Rodo Lo Rasca reis Laia a dr a ee ee ee 2 74 100 Pinion amp Valve Assembly Lock Nut a sr et es e a 26 35 Pressure Line Fitting Hydraulic Unron seese Eae head 20 27 Pump Mounting Bolts TOT G THM BOQILES boro A Pes Deu a 20 27 PES BOR ge Ae ee sok 3 35 3 3 9 RN 35 47 DIT DOE ac da ds A ds 23 31 TEM ANT E TWN TBOGEQS abra x AT S OE ADA Aa ub er 25 34 UID Oy a Aea A A O Sere res 6 cd obe ie dius 20 27 wo Body Deedee du A ah lt a sa eyed cai E NS 22 30 VET MU MEM T NS NUN ERE ON EE Ao 19 26 nk Body vu E a A A AE TE 24 33 AOO ae EE e ETE E ME ERE 37 50 MAG co Arr 18 25 Rack amp Pinion Mounting Bolt Nuts TET BOTS IAN nde tos a A A SEI 2 48 65 VET BOOY RS A RATO AS EEE WUE a nia A 2 50 68 TEN BOYS asada la AA is a e nr e d dd 2 63 85 Nue Ug qe SN BOO a A AS 2 70 95 TIT BOSS ada a da EC G 2 89 120 VIDT BOOY Mea ta daa od EE axi ds a ed 2 81 110 TWI BODY aa pde or RS OP a E E Yee AR a eae at a 2 59 80 nd coc N
7. IC 2 74 100 Steering Shaft Lower Coupling Pinch Bolt A OIE SS la ded E x RS Id Qo ete IR 9 4G aoe ope oo el rote Rd 35 47 TE TE OGM Sax ch a A ATA AA NA tse es Wate Sa ass 33 45 Oe Sc lh Vas a uiu eee ee desd eee eee ee ge ee is ee no 30 40 MIN Body tras A Ge esl Sites a Se eT es hea T 15 20 Tie Rod Adjusting Hex Lock Nut A a A RR RR RS rds 50 68 CA CU a O RR SON 55 75 TT BOOY opii Mel aah aa NR RR 44 60 TS Rod End Castre NUE maps e A A Eae 3 4 5 Transmission Mounting Nut tr Body uidet 3e mE Re ies 37 50 Wheel Ic DIS 32 ala aes a aa dada a a a ia it 100 136 1 Install NEW bolts whenever bolts are loosened or removed 2 Apply Loctite GM 1052624 to bolt threads Tighten bolts in sequence See Fig 3 3 To align cotter pin holes tighten nut a minimum of 35 fti lbs 47 Nim and a maximum ot 52 ft lbs 71 Nim DO NOT back off nut to align cotter pin holes 4 On W body tighten to 22 ft lbs 30 Nm then sn additional 115 degrees 5 On N body tighten to 15 ft lbs 20 Nm then an additional 180 degrees
8. POWER RACK amp PINION 2001 Chevrolet Camaro 2000 01 STEERING Power Rack Pinion Cars Except Prizm amp Saturn MODEL IDENTIFICATION BODY CODE IDENTIFICATION Body Code Model Jo IMADY C x vr PRX DC C NR TR M E Park Avenue oL MEM Heise payee tye SR AER AATES AAA SERA EAN AA AA a Eldorado WEM A A A MA cd e Sd Rag ad Den te Mg acta e dm Camaro amp Firebird MU tees ido eva Ad die acie Ae er oye Seine Nate A il di drea P e Ge BRE Aurora L C Bonneville amp LeSabre MA uu Qu ues Mei de IE e Cavalier amp Sunfire iu MEM TC crc PIC DeVille amp Seville MED 126 xu a da RAD a ralla ree Ri oa Alero Grand Am amp Malibu RM o a o eripi Century Grand Prix Impala Intrique Lumina Monte Carlo Regal EA A A a Gt ie ets as be ce O to dd Corvette DESCRIPTION amp OPERATION NOTE Some vehicles are equipped with Variable Effort Steering VES system identified by a solenoid on the power steering pump at the pressure line outlet See appropriate ELECTRONIC article RACK amp PINION ASSEMBLY Pump pressurizes fluid and sends it through the pump s flow control valve to the pinion and valve on the rack and pinion assembly See Fig 1 Pinion and valve direct fluid to either side of the piston and rack depending on turning direction of steering wheel Piston and rack converts hydraulic pressure into linear force reducing turning effort POWER STEERING PUMP Two types of power steering pumps are used CB series or
9. TC series These pumps are constant displacement vane type pumps See Fig 4 and Fig 5 When pressure exceeds set limits a flow control pressure relief valve opens allowing fluid to return to the inlet side of the pump Some pump applications have remote fluid reservoirs or reservoir attached to pump assembly to enable different pump mounting locations Some models have a reverse rotation pump depending upon location and belt routing LUBRICATION FLUID TYPE Use GM Power Steering Fluid 1050017 Failure to use proper fluid will cause hose and seal damage resulting in fluid leaks and damage to pump and or rack and pinion assembly CAPACITY POWER STEERING FLUID CAPACITY Application Pump Capacity System Capacity ALl Models isp tia cg Janse AA ESO BE ADEST uei aedes 1 5 Pts 0 75L FLUID LEVEL CHECK Fluid level is indicated by marks on reservoir or dipstick Ensure fluid level is at FULL COLD mark when fluid temperature is about 70 F 21 C Ensure fluid level is at FULL HOT mark when fluid is at operating temperature of about 170 F 77 C HYDRAULIC SYSTEM BLEEDING NOTE If air is introduced into hydraulic system during servicing bleed system Aerated fluid which appears Light Tan in color results in poor steering performance and may cause pump damage 1 Turn ignition off Raise and support vehicle with wheels off ground Turn wheels fully to left Add power steering fluid to FULL COLD mark on dipstick Leave cap
10. d return hoses from pump 2 Remove pump mounting bolts Remove front bracket Remove pump assembly from rear bracket 3 To install reverse removal procedure Fill and bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION Fill and bleed engine cooling system See appropriate article in ENGINE COOLING PUMP FLOW CONTROL VALVE ASSEMBLY Removal amp Installation Remove power steering pump if necessary to access rear of pump See POWER STEERING PUMP Remove pressure line fitting or VES actuator from pump See Fig 2 Remove O ring flow control valve assembly and flow control spring To install reverse removal procedure Tighten pressure line fitting to specification See TORQUE SPECIFICATIONS Flow Control Valve Assembly JOY Ring Seal Pump Assembly Fitting on G90F09994 Fig 2 Exploded View Of Flow Control Valve Assembly Typical Courtesy of General Motors Corp PUMP SHAFT SEAL Removal CB Series Pump Remove power steering pump if necessary to allow clearance for pulley removal See POWER STEERING PUMP Remove pump pulley See POWER STEERING PUMP PULLEY Protect pump shaft with shim stock Use care not to damage pump shaft surface Cut seal metal housing with small chisel to ease seal removal Use screwdriver to pry seal out of body Remove and discard seal Remove shim stock from shaft Installation Lubricate new seal with power steering fluid Using Shaft Seal Installer J 7728 or a su
11. eassembly 1 Lubricate new shaft seal O rings and all other components with power steering fluid Drive new seal into housing with Suitable socket Assemble shaft subassembly with components in original locations Ensure counterbore in center of pump rotor faces pump pulley 2 Install shaft subassembly Install remaining components Press end cover in far enough to snap retaining ring into place Install flow control valve assembly and related components Tighten hydraulic union to specification See TORQUE SPECIFICATIONS 1 Return Tube 8 Shaft 15 Pressure Plate 2 Pump Housing 9 Dowel Pin 2 16 O Ring 3 Shaft Seal 10 Thrust Plate 17 Pressure Plate Spring 4 Flow Control Spring 11 Pump Ring 18 O Ring 5 Flow Control Valve 12 Pump Vanes 10 19 End Cover 6 O Ring 13 Pump Rotor 20 Retaining Ring 7 Hydraulic Union 14 Shaft Retaining Ring G90C09997 Fig 4 Exploded View Of Power Steering Pump CB Series Courtesy of General Motors Corp POWER STEERING PUMP TC SERIES NOTE Pump is not serviceable on Seville Disassembly 1 Remove pump pulley See POWER STEERING PUMP PULLEY under REMOVAL INSTALLATION Remove shaft bearing retaining ring See Fig 5 Pull shaft and bearing assembly out of pump If removing bearing from shaft measure and record clearance if any between shaft shoulder and bearing inner race See Fig 6 Pry shaft seal from housing 2 Remove flow control fitting from pump See Fig
12. er before lowering engine frame DO NOT allow rear of engine frame to hang always support frame DO NOT allow steering column to rotate when rack and pinion is removed damage to SIR system DO NOT start engine with power steering hoses removed Serious pump damage may result Removal Except E F amp Y Bodies 1 Install Steering Column Lock Pin J 42640 into steering column if equipped Disconnect battery Raise and support vehicle Remove front wheels Separate outer tie rod ends See OUTER TIE ROD Remove steering column to rack coupler pinch bolt 2 If exhaust system interferes with removal remove front portion of exhaust system Remove any heat shields Disconnect any electrical connectors or components as necessary Disconnect sway bar if needed On Eldorado remove road sensing suspension links 3 Loosen front engine frame to body mounting bolts about one turn but DO NOT remove Install jack under rear portion of engine frame and remove rear engine frame to body mounting bolts Ensure rear of engine frame can be lowered without damaging other components Separate steering coupler from rack and pinion On Eldorado remove transaxle mount Using jack lower rear end of engine frame 4 Place a drain pan under rack and pinion Remove power Steering pressure and return lines from rack and pinion assembly Remove rack and pinion mounting bolts and bushings Remove rack and pinion from vehicle through left wheel o
13. ey Remover J 25034 on pulley hub at pump shaft While holding remover body with wrench turn center bolt clockwise to draw pull pulley off pump shaft Installation NOTE Do not use arbor press to install pulley Using Pulley Installer 7 250353 install pulley onto shaft until internal stop is contacted or face of pulley hub is even with end of shaft To complete installation reverse removal procedure Fill and bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION POWER STEERING PUMP NOTE When replacing power steering pump ensure proper replacement pump is installed Removal amp Installation Except F Body 5 7L 1 Disconnect negative battery cable Remove serpentine belt Place a drain pan under vehicle Remove or reposition as necessary coolant reservoir and power steering pump pulley See POWER SIEERING PUMP PULLEY 2 Remove air cleaner housing if necessary Remove pressure and return hoses from pump On W and G bodies remove fuel injector site shield Remove ABS wiring harness and bracket if equipped On C body remove right outer tie rod using Tie Rod Remover J 24319 01 See OUTER TIE ROD Remove pump mounting bolts Remove pump 3 To install reverse removal procedure Fill and bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION Removal amp Installation F Body 5 7L 1 Remove pump pulley if necessary See POWER STEERING PUMP PULLEY Remove pressure an
14. g To prevent internal damage hold rack with a backup wrench during tie rod installation Apply Loctite No 262 to inner tie rod threads Install inner tie rod onto rack Tighten inner tie rod to specification See TORQUE SPECIFICATIONS Stake tie rod fittings as shown in illustration See Fig 11 2 Ensure inner tie rod pivots freely in all directions and then stake both sides of inner tie rod to flats on rack See Fig 11 Ensure both stakes are okay by inserting a 010 25 mm feeler gauge between rack and tie rod housing Feeler gauge must not pass between rack and housing stakes 3 To complete reassembly reverse disassembly procedure Apply grease to inner tie rod and housing before installing boots Install outer tie rod end with same number of turns as when removed Install new cotter pin at castle nut DO NOT back off castle nut to install cotter pin Adjust toe in as necessary See appropriate SPECIFICATIONS amp PROCEDURES article in WHEEL ALIGNMENT Fill and bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION Inner Tie Rod Assembly Shock Damper Hing E N e Stake Both Sides Of Housing Sr m B owe IG NS Support Housing When Staking Insert 010 25 mm Feeler Gauge Here Feeler Gauge Must Not Pass Between Rack amp Housing Stake On Either Side G90E10003 Fig 11 Staking amp Inspecting Inner Tie Rod Courtesy of General Motors Corp TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS
15. g is even with annulus 4 Align notch on valve stub shaft with second mark made during disassembly Using ring protector and Pinion Seal Installer J 29822 push pinion and valve assembly into housing bore DO NOT hammer or use excessive force If assembly does not fully seat in housing ensure valve body rings are not binding in bore 5 After assembly is seated in bore ensure notch in stub shaft and first mark on housing are aligned While holding stub shaft to prevent damage to pinion teeth install adjuster plug lock nut and tighten to specification See TORQUE SPECIFICATIONS 6 Install dust cover Install stub shaft bearing annulus assembly onto pinion and valve stub shaft Install Seal Protector J 29810 onto valve stub shaft Apply a small amount of grease between stub shaft seal and stub shaft dust seal Install seals over protector and into housing Install retaining ring into groove in housing 7 Lubricate stub shaft and dust seal area with grease Coat rack bearing adjuster spring and adjuster plug with grease and install into housing With rack centered in housing turn adjuster plug clockwise until it bottoms in housing then back off 50 70 degrees about one flat Using an INCH lb torque wrench check pinion torque Maximum pinion preload torque is 16 INCH lbs 1 8 N m 8 Install adjuster plug lock nut onto adjuster plug While holding adjuster plug tighten lock nut to specification Install rack and pinion assemb
16. itable size deep socket drive seal into housing until it bottoms Install pulley onto pump See POWER STEERING PUMP PULLEY Install pump onto bracket if removed Removal IC Series Pump Remove power steering pump if necessary to allow clearance for pulley removal See POWER STEERING PUMP Remove pump pulley See POWER STEERING PUMP PULLEY Remove bearing retaining ring Removal drive shaft and bearing assembly Use screwdriver to pry seal out of body Remove and discard seal If replacing bearing measure clearance if any between drive shaft shoulder and bearing inner race See Fig 6 Installation Lubricate new seal with power steering fluid Using suitable size deep socket drive seal into housing until it bottoms Press bearing onto shaft to clearance measured before removal Install shaft and bearing into housing rotating assembly to engage rotor Install bearing retaining ring with beveled side down indicated by position of large lug on ring See Fig 7 Install pulley onto pump Install pump onto bracket if removed RACK amp PINION ASSEMBLY CAUTION To prevent damage to Supplemental Inflatable Restraint SIR system place front wheels in a straight ahead position and turn ignition switch to the LOCK position Follow these precautions if applicable when removing rack and pinion from vehicle Before disconnecting battery see COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION Disconnect steering column coupl
17. l and stub shaft bearing annulus race assembly Remove pinion and valve assembly with retaining ring and valve body rings attached Carefully remove valve body rings from pinion and valve assembly Center Rack amp Mark Location Of Stub Shaft Notch On Housing 4 Housing Assembly e Location Of Notch May Pinion amp Valve Vary With Each Model Assembly b 9 9 o 9 Q Po CQ d GB hb e b m amp 5b Ss Bo b 9 98 Po d 4 5 9 5 b b 5 T DP hb ease D Tie Rod Boot 95413417 Fig 8 Marking Housing Measuring Tie Rod Boot For Reassembly Reference Courtesy of General Motors Corp Inspection Clean valve body ring grooves Check pinion and valve assembly drive pin If pin is broken replace rack and pinion assembly Reassembly 1 Apply grease to ring grooves See Fig 9 Install new valve body rings on pinion and valve assembly ensuring split tabs are engaged and staggered Use care not to cut rings during installation Apply grease to valve body rings 2 Install pinion and valve assembly into Ring Protector J 37090 See Fig 10 Position valve assembly in ring protector so valve body is even with bottom of protector Allow rings to rest inside ring protector for about 3 minutes so valve rings will size properly 3 Using measurement taken during disassembly as a guide center rack in housing Clean and apply grease to housing bore Ensure Stub shaft bearing annulus race is not damaged and bearin
18. l fluid reaches operating temperature stop engine Check fluid level Add fluid if necessary Start engine Pressure should be less than 230 psi 16 8 kg cm If pressure exceeds 230 psi 16 8 kg cm stop engine and check for restriction in hose s CAUTION To prevent pump damage Do not hold gauge valve closed for more than 5 seconds 3 While observing pressure gauge fully close valve for less than 5 seconds and then open it Repeat process 2 more times and record highest pressure displayed each time valve is closed If readings are as specified and within 50 psi 4 kg cm of each other go to step 6 See PRESSURE RELIEF SPECIFICATIONS table If readings are as specified but not within 50 psi 4 kg cm of each other go to next step If readings are not as specified but within 50 psi 4 kg cm of each other go to step 5 PRESSURE RELIEF SPECIFICATIONS Application psi degJ uuwW ETE MAN BOTES oru nee deaxtener Be en UR More Than 1350 95 uo uoo A Nro c P ee E More Than 1500 105 CIS BOY Marcar ssl Scale Sota A erm a a More Than 1200 84 TOY ZE UE BOSS sacada d More Than 1700 120 gu Body A A E bl ade yk a tes Gy eee a A More Than 1200 84 Popes de ela RDN ere hres A Eta tesla us Rr oe Boo tS Oe is td ear ax More Than 1300 91 WI o Gonedeckiohe ice Gace eee oe Seek ee ee ee More Than 1400 98 WN o a ranch eS O A ee c ae d More Than 1300 91 WEY BON A o See boot Bhs are OG Be More Than 1250 89 4 Check fo
19. lding adjuster plug stationary tighten adjuster plug lock nut to specification See TORQUE SPECIFICATIONS Test drive vehicle ensuring steering wheel returns to center after turning Shock Damper Ring Bulkhead Retainer Ring Retaining Ring Outer Cylinder Bulkhead Stub Shaft Dust Seal O Ring Needle Bearing TR Rack amp Pinion Bulkhead Seal Stub Shaft ae Race M rr Wave Washer Valve Body Rings 4 amp Piston O Ring Pinion amp Valve NS Stub Shaft Seal 1 Pa a Piston amp Rack Rack amp A Seal S Retaining Ring Su Housing E Upper Pinion Bushing Pinion Boot P BE Inner dl l Y Boot Clamp Rod End s pastel M lug Pede duae Mounting Ball Bearing Adjuster yr e Grommet ET Sonn mS Dust Cover pring a Adjuster Plug Inner Tie Rod A a COCK Nut o i 2 VIEW AA 2 A Tis Outer Tie Boot Clamp S Rod End G95113415 Fig 1 Exploded View Of Power Rack amp Pinion Steering Assembly Typical Courtesy of General Motors Corp SYSTEM TESTS NOTE Incorrect idle speed fluid level belt tension as well as a damaged pump pulley can affect test results If any of these conditions exist repair as necessary before testing power steering system PRESSURE TEST 1 Disconnect high pressure line from power steering pump Connect power steering pressure tester gauge between high pressure line and power steering pump using appropriate adapters Completely open tester valve 2 Run engine unti
20. ly Fill and bleed system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION Apply Grease To Ring Grooves lab NOTE Ensure rings are installed with split tabs engaged and staggered Pinion amp Valve Assembly Apply Grease To Rings After Assembly 395B13418 Fig 9 Installing Valve Body Rings Courtesy of General Motors Corp Valve Body Hing Ensure Valve Body ls Flush With Bottom Of Ring Protector 7 Limia nr hr F JE LEAL 4 LE dl t LE d ib tit pr 4 FEE ropa eee AL de TEE Lippe r AT A A AF A m A IN ELLA IA PO lt P 195013419 Fig 10 Setting Valve Body Rings Courtesy of General Motors Corp INNER TIE ROD Disassembly 1 Remove outer tie rod end from inner tie rod noting number of turns required for removal Remove hex jam nut from inner tie rod Remove adjusting nut from inner tie rod Remove outer boot clamp Cut off and discard inner boot clamp Mark location of breather tube if equipped for reassembly reference Slide boot from inner tie rod 2 Slide shock damper ring on inner tie rod assembly back toward rack Place a wrench on flat side of rack to prevent turning Place another wrench on flats of inner tie rod Rotate inner tie rod counterclockwise until it separates from piston and rack On C r N and Y bodies clean old Loctite from threads of rack and inner tie rod Remove shock damper ring Reassembly 1 Install shock damper rin
21. ng groove 4 Install thrust plate ensuring dimples in thrust plate align with mounting holes in housing and thrust plate holes engage pump ring dowel pins Press thrust plate into housing far enough to install retaining ring Install retaining ring with opening centered on mounting boss nearest access hole 5 Press shaft bearing onto shaft until clearance between inner race and shoulder is same as clearance recorded during removal See Fig 7 Slide shaft and bearing assembly into housing rotating assembly to align splines of shaft and rotor Install bearing retaining ring with beveled side down indicated by position of large lug ou ring Install pulley on pump E 15 p 14 10 13 11 12 1 2 3 D p j 1 Retaining Ring 9 Pump Housing 2 Shaft Bearing 10 Return Tube 3 Shaft 11 Dowel Pin 4 Shaft Seal 12 Sleeve 5 Flow Control Fitting 13 O Ring 6 O Ring 14 Pressure Plate Spring 7 Flow Control Valve 15 O Ring 8 Flow Control Spring 16 Pressure Plate G90D09993 Fig 5 Exploded View Of Power Steering Pump TC Series Courtesy of General Motors Corp When Clearance Exists Between Drive Shaft Shoulder amp Bearing Race Measure Clearance Before Removing Bearing Feeler Gauge Shaft 390109995 Fig 6 Measuring Shaft Bearing Clearance TC Series Courtesy of General Motors Corp 17 Dowel Pins 18 Pump Vanes 10 19 Pump Rotor 20 Cam Ring Pump Ring 21 O Ring 22 Thrust Plate 23
22. on See TORQUE SPECIFICATIONS To complete installation reverse removal procedure Tighten tie rod end castle nut to specification Install NEW cotter pin at castle nut DO NOT back off nut to install cotter pin Adjust toe in as necessary RACK amp PINION BOOTS Removal Remove outer tie rod See OUTER TIE ROD Remove outer to inner tie rod lock nut Remove outer boot clamp Cut off and discard inner boot clamp When replacing both rack boots mark location of breather tube to rack if equipped for installation reference Remove breather tube DO NOT remove breather tube if only replacing one boot Slide boot from inner tie rod Installation 1 Place NEW inner clamp onto boot Install breather tube if removed aligning tube as marked during removal Install boot If necessary apply thin coat of grease onto inner tie rod shaft except threads and boot clamping area onto housing to aid in installation Ensure boot is not twisted or out of shape Ensure breather tube is in proper notch position in boot 2 Crimp inner clamp using Banding Tool J 22610 Install outer clamp Install outer tie rod end Tighten outer to inner tie rod lock nut to specification See TORQUE SPECIFICATIONS To complete installation reverse removal procedure Adjust toe in as necessary POWER STEERING PUMP PULLEY Removal It may be necessary to remove or reposition power steering pump to remove pulley If necessary see POWER STEERING PUMP Install Pull
23. ove air intake resonator On all models place drain pan under vehicle and drain power steering fluid Raise and support vehicle Remove front wheels Support engine with suitable jack Disconnect power steering pressure and return hoses from rack and pinion assembly 2 Remove steering coupler pinch bolts and remove coupler from rack and pinion Disconnect and separate front tie rod ends See OUTER TIE ROD On V8 remove generator On V8 remove left side engine mount through bolt On all models remove rack and pinion mounting bolts and nuts Remove rack and pinion Installation To install reverse removal procedures Tighten nuts and bolts to specification See TORQUE SPECIFICATIONS Fill and bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under lubrication Adjust toe in as necessary See appropriate SPECIFICATIONS amp PROCEDURES article in WHEEL ALIGNMENT Removal Y Body 1 Disconnect negative battery cable Remove brake pressure modulator valve BPMV bracket Place drain pan under vehicle and drain P S fluid Remove intermediate shaft shield Disconnect power Steering pressure and return hoses from rack and pinion assembly Disconnect power steering cooler and remove from vehicle Remove steering coupler pinch bolts and remove coupler from rack and pinion 2 Raise and support vehicle Remove front wheels Disconnect and separate front tie rod ends See OUTER TIE ROD Disconnect electrical connectors Remove stabilizer
24. pening on most models Installation To install reverse removal procedures Tighten nuts and bolts to specifications Apply Loctite to threads and tighten in Sequence See Fig 3 See TORQUE SPECIFICATIONS Fill and bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION Adjust toe in as necessary See appropriate SPECIFICATIONS amp PROCEDURES article in WHEEL ALIGNMENT Removal E Body 1 Disconnect battery Raise and support vehicle Remove front wheels Remove power steering pressure hoses from rack and pinion Separate outer tie rod ends See OUTER TIE ROD Remove Steering column to rack coupler pinch bolt 2 Support front suspension crossmember with a suitable jack Remove brake pipes from the retainers on the front suspension support Remove front suspension crossmember mounting bolts Lower front Suspension crossmember in order to remove rack and pinion Remove rack and pinion mounting bolts Remove rack and pinion from front Suspension crossmember Installation To install reverse removal procedures Tighten nuts and bolts to specifications Apply Loctite to threads and tighten in sequence See TORQUE SPECIFICATIONS Fill and bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION Adjust toe in as necessary See appropriate SPECIFICATIONS amp PROCEDURES article in WHEEL ALIGNMENT Removal F Body 1 Disconnect negative battery cable Remove serpentine belt if needed On V8 rem
25. r sticking flow control valve Remove valve but DO NOT disassemble Clean valve using crocus cloth or fine hone Flush system if dirty Install valve and retest system If readings are now as specified go to step 6 If reading are not as specified go to next step 5 Replace flow control valve and retest system If pressure readings are still low check pump rotor and vanes for wear Replace complete pump assembly if worn and flush power steering system If pressure readings are as specified go to step 7 6 With valve open turn steering wheel from stop to stop Record highest pressure with wheels at both stops If highest pressure is not equal to highest pressure recorded in step 3 rack and pinion assembly is leaking internally Repair or replace assembly If pressures are equal no problem exists Go to next step 7 Turn engine off Remove tester Reconnect high pressure hose to pump Check fluid level Bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION FLOW RATE TEST 1 Connect Power Steering Analyzer J 44721 into system Fully open analyzer valve Run engine until fluid reaches normal operating temperature Check fluid level Add fluid if necessary Record pressure and flow rate 2 Close valve partially until pressure is 700 psi 49 kg cm and then record flow rate Subtract flow rate from that measured in step 1 If flow rate drops more than one gallon 3 8L per minute replace ring rotor and vanes
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