Service Procedure
CK Repair ProcedureTools Required
^ J 25034-C Power Steering Pump Pulley Remover
^ J 25033-C Power Steering Pump Pulley Installer
^ J 43485 Power Steering Bleeder Adapter
^ J 3555 Metal Mityvac
1. Place a drain pan below the pump.
2. Remove the hoses.
3. Cap the hoses.
4. Install a 3/8 inch drive wrench on the drive belt tensioner and rotate the arm counterclockwise.
5. Remove the drive belt.
6. Slowly release the tension on the drive belt tensioner.
7. Remove the power steering pump pulley.
A. Install the J 25034-C pulley remover.
B. Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.
C. Hold the pilot bolt.
D. Turn the nut counterclockwise.
8. Remove the front mounting bolts.
9. Remove the rear mounting nuts from the studs.
10. Remove the electrical connector from the EVO actuator.
11. Remove the pump.
12. Perform the following on EVO equipped pumps only:
^ Mark the orientation of the EVO on the pump.
A. Remove the EVO actuator and discharge fitting from the original pump.
B. Remove the 0-ring seal from the EVO actuator and properly discard.
C. Remove the fitting assembly from the replacement pump and carefully remove the 0-ring seal before properly discarding the fitting.
D. Lubricate the new 0-ring seal removed from the replacement pump fitting with clean power steering fluid and install in correct groove in the EVO actuator.
E. Install the original EVO actuator and discharge fitting on the replacement pump, noting the correct orientation.
Tighten
Tighten the EVO actuator assembly to 50 Nm (37 lb-ft).
13. Install the new pump.
Notice:
Refer to Fastener Notice in Cautions and Notices.
14. Install the front mounting bolts.
Tighten
Tighten the bolts to 50 Nm (37 lb-ft).
15. Install the rear mounting nuts to the studs.
Tighten
Tighten the nuts to 50 Nm (37 lb-ft).
16. Install the pulley.
^ Place the pulley on the end of the pump shaft.
A. Install the J 25033-C.
B. Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.
C. Hold the pilot bolt.
D. Turn the nut clockwise.
E. Connect the pulley to the end of the power steering pump shaft.
17. Install the pulley flush with 0.5 mm (0.020 in) play.
18. Route the belt over all the pulleys except the drive belt tensioner.
19. Install a 3/8 inch drive wrench on the drive belt tensioner and rotate the drive belt tensioner arm counterclockwise.
20. Install the belt over the drive belt tensioner pulley.
21. Slowly release the tension no the drive belt tensioner pulley.
22. Confirm that the belt is properly routed.
23. Install the hoses.
24. Install the electrical connector to the EVO actuator.
Important:
Hoses touching the frame, body or engine may cause system noise.
25. Verify that the hoses do not touch any other part of the vehicle.
Important:
Loose connections may not leak, but could allow air into the steering system.
26. Verify that all hose connections are tight.
Important:
Maintain the fluid level throughout the bleed procedure.
27. Remove the pump reservoir cap.
Important:
Use clean, new power steering fluid only.
28. Fill the pump reservoir with fluid to the FULL COLD level.
29. Attach the J 43485 to the J 35555 or equivalent.
30. Place the J 43485 on or in the pump reservoir filler neck.
31. Apply a vacuum of 68 kpa (20 in Hg) maximum.
32. Wait 1 minute.
33. Remove the J 43485 and the J 35555.
34. Reinstall the pump reservoir cap.
35. Start the engine. Allow the engine to idle.
36. Turn the steering wheel 180-360 degrees in both directions 5 times.
37. Switch the ignition off
38. Verify the fluid level.
G Van Repair Procedure
Tools Required
^ J 25034-C Power Steering Pump Pulley Remover
^ J 25033-C Power Steering Pump Pulley Installer
^ J 43485 Power Steering Bleeder Adapter
^ J 3555 Metal Mityvac
1. Place a drain pan below the pump.
2. Loosen the air cleaner duct clamp.
3. Remove the air cleaner assembly bolts.
4. Remove the air cleaner assembly.
5. Drain coolant from the recovery reservoir.
6. Remove the coolant recovery reservoir-retaining bolt.
7. Remove the coolant recovery reservoir hose clamp and the hose at the radiator fitting.
8. Remove the coolant recovery reservoir from the cowl tabs and the vehicle.
9. Remove the dipstick bracket bolt at the generator.
10. Remove the engine oil and transmission fluid dipsticks.
11. Remove the upper fan shroud retaining bolts from the top of the radiator.
12. Remove the upper to lower fan shroud retaining bolts.
13. Remove the upper fan shroud from the vehicle.
14. Remove the fan and clutch assembly.
15. Install a 3/8 inch drive wrench on the drive belt tensioner and rotate the arm counterclockwise.
16. Remove the drive belt.
17. Slowly release the tension on the drive belt tensioner.
18. Remove the power steering pump pulley.
A. Install the J 25034-C pulley remover.
B. Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.
C. Hold the pilot bolt.
D. Turn the nut counterclockwise.
19. Remove the air conditioning compressor mounting bolts and support compressor with wire.
20. Remove upper radiator hose support bracket.
21. Remove power steering pump bolts (5).
22. Remove power steering pump bracket (1).
23. Remove the reservoir hose from the pump.
24. Loosen adjusting nuts (4).
25. Remove pressure line from pump and raise it to prevent drainage.
26. Remove the return line from the pump and raise it to prevent drainage.
27. Cap the ends of the hoses to prevent entry of dirt.
28. Remove the electrical connector from EVO actuator, if equipped.
29. Remove the pump.
30. Perform the following on EVO equipped pumps only:
^ Mark the orientation of the EVO on the pump.
A. Remove the EVO actuator and discharge fitting from the original pump.
B. Remove the 0-ring seal from the EVO actuator and properly discard.
C. Remove the fitting assembly from the replacement pump and carefully remove the 0-ring seal before properly discarding the fitting.
D. Lubricate new 0-ring seal removed from the replacement pump fitting with clean power steering fluid and install in correct groove in the EVO actuator.
E. Install the original EVO actuator and discharge fitting on the replacement pump noting the correct orientation.
Tighten
Tighten the EVO actuator assembly to 50 Nm (37 lb-ft.).
31. Transfer rear bracket to replacement pump.
32. Install the new pump on the rear mounting studs.
Notice:
Refer to Fastener Notice in Cautions and Notices.
33. Install the pressure line to the pump.
34. Tighten the fitting.
Tighten
Tighten to 27 Nm (20 lb-ft).
35. Install the return line to the pump.
36. Install reservoir hose to the pump.
37. Install the power steering pump bracket.
38. Install bracket bolts and nut and finger tighten.
39. Install power steering pump bolts and finger tighten.
40. Tighten bracket bolts and nut.
Tighten
Tighten to 41 Nm (30 lb-ft).
41. Tighten power steering pump bolts and nuts.
Tighten
Tighten to 50 Nm (37 lb-ft).
42. Install air conditioning compressor and bolts.
Tighten
Tighten to 50 Nm (37 lb-ft).
43. Install upper radiator hose support bracket.
44. Install the pulley.
^ Place the pulley on the end of the pump shaft.
A. Install the J 25033-C.
B. Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.
C. Hold the pilot bolt.
D. Turn the nut clockwise.
E. Connect the pulley to the end of the power steering pump shaft.
45. Install the pulley flush with 0.5 mm (0.020 in) play.
46. Route the belt over all the pulleys except the drive belt tensioner.
47. Install a 3/8 inch drive wrench on the drive belt tensioner and rotate the drive belt tensioner arm counterclockwise.
48. Install the belt over the drive belt tensioner pulley.
49. Slowly release the tension on the drive belt tensioner.
50. Confirm that the belt is properly routed.
51. Install the electrical connector to the EVO actuator, if equipped.
52. Install cooling fan and clutch assembly.
^ Tighten
^ All except 7.4L - Tighten to 57 Nm (42 lb-ft).
^ 7.4L only - Tighten to 24 Nm (18 lb-ft).
53. Install upper fan shroud into the vehicle.
54. Install the upper fan shroud retaining bolts.
Tighten
Tighten the bolts to 8 Nm (71 lb-in).
55. Install the dipstick tube bracket bolt at the generator.
56. Install coolant reservoir hose and clamp.
57. Install coolant reservoir to cowl.
58. Install coolant reservoir bolt.
Tighten
Tighten to 11 Nm (97 lb-in).
59. Install the engine oil and transmission fluid dipsticks.
60. Install the air cleaner assembly.
61. Install the air cleaner assembly bolts.
Tighten
Tighten to 18 Nm (13 lb-ft).
62. Refill coolant reservoir to the proper mark.
Important:
Hoses touching the frame, body or engine may cause system noise.
63. Verify that the hoses do not touch any other part of the vehicle.
Important:
Loose connections may not leak, but could allow air into the steering system.
64. Verify that all hose connections are tight.
Important:
Maintain the fluid level throughout the bleed procedure.
65. Remove the pump reservoir cap.
Important:
Use clean, new power steering fluid only.
66. Fill the pump reservoir with fluid to the FULL COLD level.
67. Attach the J 43485 to the J 35555 or equivalent.
68. Place the J 43485 on or in the pump reservoir filler neck.
69. Apply a vacuum of 68 kpa (20 in Hg) maximum.
70. Wait 1 minute.
71. Remove the J 43485 and the J 35555.
72. Reinstall the pump reservoir cap.
Important:
Do not turn steering wheel to lock.
73. Start the engine. Allow the engine to idle.
74. Turn the steering wheel 180-360 degrees in both directions 5 times.
75. Switch the ignition off
76. Verify the fluid level.