SECTION 9A - STEERING

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either

seat belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and a driver's and front

passenger's air b ags or seat belt pre- tensioners, driv er’s and front passenger’s air bag and left and right

hand side air bags. Refer to SAFETY PRECAUTIONS, Section 12M, Supplemental Restraint System in this

Service Information before performing any service operation on, or around any SRS components, the

steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could result in SRS

deployment, resulting in possible personal injury or unnecessary SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). In the interests of safety, the LPG fuel

system should be isolated by turning ‘OFF’ the manual service valve and then draining the LPG service

lines, before any service work is carried out on the vehicle. Refer to the LPG leaflet included with the

Owner's Handbook for details or the appropriate Section of this Service CD for more specific servicing

information.

CAUTION:

Whenever any component that forms part of the ABS or ABS/ETC (if fitted), is disturbed during Service

Operations, it is vital that the complete ABS or ABS/ETC system is checked, using the procedure as

detailed in 4. DIAGNOSIS, ABS or ABS/ET C FUNCT ION CHECK, in Section 12L ABS & ABS/ETC, of the VT

Series I Service Information or the VT Series II Service Information.

1. GENERAL INFORMATION

With the introduction of VT Series II vehicles, a revised design steering rack is fitted. The revised design

incorporates the pinion rotary valve housing as a single piece casting integral with the steering rack body casting.

This single piece casting steering rack is only used on those vehicles fitted with the standard power steering.

As the remainder of service operations are the same as those published in Section 9A STEERING and

Section 9B SPEED SENSITIVE POWER STEERING of the VT Series I Service Information, refer to these Sections

for all operations not described here.

Essentially, the service item s covered in this Sec tion relate to the new design steering rack and the power steering

pump and fluid cooler, as fitted to the GEN III V8 engine.

1.1 GENERAL DESCRIPTION - POWER STEERING RACK AND PINION

While the operation of the revised designpower steering gear remains unchanged, this general description is

included, to provide a more complete service operation description.

The power steering gear features a variable ratio rack and pinion that is m ade possible by the unique design of the

rack teeth. This means that the effective pitch radius of the pinion is less in the straight ahead position than on

turns. T his results in less turns being required fr om loc k to lock . For ex ample, 3.5 turns would be required if the ‘on

centre’ ratio was used from lock to lock, whereas only 2.7 turns are required with this rack design.

Referring to Figure 9A-1, the helical toothed pinion (8) is supported in the steering gear housing (2) by a needle

roller bearing (13) at the upper end, a ball race (14) at the lower and a roller bearing (17) at the upper end of the

pinion teeth.

The rack (16) operates within the housing and is supported at one end by a rack bearing and at the other end by the

pinion (8) and a spring loaded pad (15), which maintains slack free adjustment of the rack (16) with the pinion (8).

The tie rods ar e connected to each end of the rack by pre-ass embled ball j oints and to the steering arm s by tie rod

end ball joints.

Techline

PRINCIPLES OF OPERATION

With the engine running and the steering wheel in

the neutral position (straight ahead), fluid flows

continuously from the power steering pump to the

steering gear and back to the pump, via the fluid

reservoir. In this steering mode, very little pressure

is required to maintain the high fluid flow rate that

occurs at this time. As a result, little engine power

is required to operate the system.

When turning the s teer ing wheel to either side, f luid

flow from the pump is directed by a rotary control

valve fitted to the steering gear, to whichever side

of the rack piston is appropriate, as indicated by the

steering wheel position. The fluid pressure then

increases as necessary, to provide the required

steering assistance.

This rotary control valve assembly, is located

between the input shaft (1) and the pinion (8), in the

steering gear.

As shown, the rotary valve assem bly consists of an

inner member (1) which forms part of the input

shaft and a surrounding sleeve member (2). The

whole valve, rotates in the steering gear housing

(3) as the steering wheel is turned, but it is the

slight relative movement of the inner and the sleeve

members that controls and directs the power

steering fluid flow.

Fluid is fed to the valve (➨) and from there, to the

left (4) and right (5) sides of the power piston via

circum f erential gr ooves in the outer sleeve, that are

sealed by PTFE seals (6). Excess fluid is returned

to the reservoir.

The outer s leeve is coupled by a stepped pin (7) to

the rack pinion (8), while the input shaft (1) is

coupled to the rack pinion by a pinned (9), flexible,

torsion bar (10) that provides a mechanical but

flexible link between the two members.

In the straight ahead position, the valve remains

centred. As steering effort requirements increase,

the torsion bar flexes, causing slight relative

rotation between the input shaft and sleeve,

directing fluid and providing power assistance as

needed.

Figure 9A-1

A Rack Gain B Rack Travel 1 Clamp Bolt Flat

Figure 9A-2 - Power Steering Gear

FLUID FLOW

NEUTRAL POSITION (STRAIGHT AHEAD)

From the s tylised cross - s ect ioned view of the r otary

valve shown in Figure 9A-3, it can be seen that in

this attitude, fluid f low from the pum p ( 4) is dire cted

into the cavities (Shown as ‘A’). of the inner valve

assembly (1) and out through a number of drilled

holes in the outer sleeve (2) (Shown as ‘B’). In this

steering position, the inner valve (1) allows fluid to

pass equally to both sides of the rack (3) piston

(shown as 'Static' because no f luid actually flows to

and from the steering gear). The bypassed fluid

returns to the fluid reservoir (5) through holes

drilled in the longitudinal grooves of the inner valve.

W ith an equal pr essure applied to both sides of the

rack piston, no power assistance is provided.

Figure 9A-3

TURNING RIGHT

When turning to the right, as soon as relative

motion between the inner rotating valve (1) and

outer sleeve (2) occurs, fluid is restricted in its free

return to the pump and is routed to the right hand

side of the rack piston. At the same time, fluid on

the opposite side of the piston is directed to the

return circuit, leading to the reser voir (5) and pump

(4). This action is slight at first, providing only a

small amount of driver assistance, but becomes

progressively greater with a higher steering load

that causes the torsion bar in the rotary valve

assembly, to tw ist.

Figure 9A-4

TURNING LEFT

When turning left, the opposite situation occurs.

That is, once the relative m otion between the inner

valve (1) and the outer sleeve (2) causes a return

restric tion, f luid is routed to the lef t hand side of the

rack piston (3), providing the required assistance.

Also, fluid on the opposite side of the piston is free

to flow back to the reservoir (5) and the pump (4),

through the return circuit. As before, the am ount of

assistance provided by the fluid, is determined by

the res triction caused by the interaction of the inner

valve and outer rotary sleeve. This is controlled by

the twisting of the torsion bar connected between

these two valve members.

Figure 9A-5

INNER VALVE MEMBER

W hen parking, more than 90% of the work is done

by the fluid. In order to achieve a balance between

this graduated increase of assistance and maintain

a realistic 'feel' with good response as the road

speed increases, the grooves (2) of the inner

rotating valve (1) ar e precisely shaped to meter the

flow of oil.

Note that under extreme load conditions or when

for any reason, the hydraulic system is inoperative,

the torsion bar is able to deflect suf ficiently to allow

the input shaft to drive the steering pinion directly.

This is achieved by having a loose fitting spline

between the lower end of the input shaft and the

surrounding upper end of the pinion. Under these

operating conditions, steering loads will be high and

a noticeable amount of slack will develop because

of the torsion bar flexing. Therefore, while the

steering gear rem ains entir ely operable, the vehicle

should only be operated in this manner for the

minimum distance needed to reach a point where

the system can be serviced.

Figure 9A-6

1.2 GEN III V8 ENGINE POWER STEERING PUMP

In design and operation, the power steering pump

fitted to the GEN III V8 engine is the s ame as the ‘N’

series pump fitted to V6 engined VT series vehicles.

PUMP CONSTRUCTION

In the rear of the pump housing (1), a cavity

contains the following parts: pump ring (2), pump

rotor (3) and vanes (4), splined to the drive shaft (5)

and thrust (6) and pressure plates (7).

A sm aller cavity, below the larger one, contains the

flow control assembly (8), consisting of a control

valve assembly and pump outlet fitting (9) with

control needle and spring.

Figure 9A-7

2. STEERING COLUMN ASSEM BLY SERVICE OPERATIONS

2.1 STEERING COLUMN ASSEMBLY SERVICE NOTES AND PRECAUTIONS

CAUTION: Disable the SRS (Air Bag). Refer to ‘DISABLING THE SRS’, in Section 12M of this Service

Information.

CAUTIONARY NOTES:

1. The outer j ack et, steering shaf t and instrum ent panel mounting br acket are designed as energy absorbing units.

Because of the design of these components, it is absolutely vital that the steering column assembly is handled

with care when perform ing any of the required s ervice oper ations. Avoid ham m ering, j arring, dropping or leaning

on any portion of the column.

2. All steering wheel and column fasteners are important parts in that they could affect the performance of other

vital parts and systems.

3. Fasteners must be replaced with those of the same part number or with an equivalent part, if replacement is

required. Do not use a replacement part of lesser quality or substitute design.

4. Torque values must be used where specified during reassembly to assure proper retention of the part.

NOTE: For all service operations relating to the steering column and associated components, refer to

Steering 9A STEERING, of the VT Series I Service Information.

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3. POWER STEERING SERVICE OPERATIONS

3.1 FLUID LEVEL CHECK

NOTE: The recommended fluid for use in all VT

series vehicles, is Dexron® III automatic

transmission fluid to Holden’s Specification HN2126.

V6 ENGINE

Refer to Steering 9A STEERING of the VT Series I

Service Information for information relating to this

service operation.

GEN III V8 ENGINE

The power steering fluid level can be checked by

viewing the level through the translucent plastic

side of the reservoir. There is no need to remove

the engine dress cover for this operation.

If the f luid is cold, the level should be in the ‘COLD’

range. Similarly, if it is hot, the f luid should be in the

‘HOT’ range. If the fluid level is at the low side of

either range, new fluid should be added to bring the

level to the correct point and the system checked

for the cause of the leakage and corrected as

necessary.

Figure 9A-8

3.2 DRIVE BELT ADJUSTMENT

V6 ENGINE

For vehicles with V6 engine, the power steering pum p is driven by the engine serpentine drive belt. T he belt is self

adjusting within tensioner operating limits. For details, refer to Section 6A1, ENGINE MECHANICAL of the VT

Series I Service Information.

GEN III V8 ENGINE

For vehic les with the GEN III V8 engine, the power steer ing pum p is driven by the engine serpentine drive belt. T he

belt is self adjusting within tensioner operating limits. For details, refer to Section 6B3, GEN III V8 ENGINE

COOLING of the VT Series II Service Information.

3.3 HYDRAULIC SYSTEM, BLEEDING/REFILLING P ROCEDURE

CAUTIONARY NOTES:

1. If the fluid level is low in the fluid reservoir, air will be drawn in and mixed with the fluid in sm all bubbles. If the

pump is allowed to continue operation, an increasing amount of air will be drawn into the system, causing the

fluid volum e to increas e to a point where the reservoir will overflow. Sudden releases in pressure that will occur

when the steering is suddenly taken off a ‘full lock’ condition, will cause dramatic eruptions of fluid from the

reservoir. The separation of air entrapped under these conditions will be extremely difficult to remove and may

take several days.

2. If the steering rack assembly requires replacement, a large volume of air will be required to be purged, which

means that the reservoir fluid level will fall rapidly when the engine is started.

3. During bleeding, it is important that the front wheels are clear of the ground and that the steering is not held

forcibly against the steering stops.

BLEEDING/REFILLING PROCEDURE

1. Raise front of vehicle and place on safety stands. Refer to Section 0A, GENERAL INFORMATION of the VT

Series I Service Information.

2. W ith engine not r unning, add fluid to reservoir to the m aximum mar k (or greater , if it is known that the steering

gear is empty).

3. Start engine and allow to run for only 2-3 seconds. Do not turn the steering wheel at this point.

4. Continue with Steps 2 and 3 until the fluid level remains constant.

5. Start and run the engine at idle speed, turning the steering wheel from lock to lock, without holding at the full

lock positions (this will build up high pressures, atomising any entrapped air). Repeat this procedure from six to

eight times. Stop the engine, check the fluid level and top up to the maximum level, as required.

6. Start and run the engine at idle speed. Again turn the steering wheel from lock to lock but now slowly build up

the pressure levels by holding against the full lock position from 1-2 seconds. Repeat this procedure f rom four

to six times. Stop the engine and top up the fluid level to the maximum mark, as required.

NOTE: While the majority of entrapped air will be removed by the above process, a small amount may remain,

which can only be removed by alternate circulation and settling of the fluid for a prolonged period. This is usually

achieved automatically after two to three day s, with daily driving and settling overnight.

7. Turn the steering wheel to the straight ahead position, lower vehicle to the ground and turn ignition ‘OFF’.

3.4 HYDRAULIC SYSTEM, CHECK

The f ollowing procedur es outline methods to identif y and isolate power steering hydraulic circ uit dif f ic ulties . T his test

is divided into two parts. Test number one provides a means of determining whether the power steering system

hydraulic parts are faulty. If test number one results in readings indicating faulty hydraulic operation, test number

two will identify the faulty part.

Before perfor ming the hydraulic circuit tes t, caref ully check the fluid level, drive belt c ondition and tension, idler and

driving pulleys for smooth operation.

The engine must be at normal operating temperature and the front tyres inflated to the correct pressure. All tests

are made with engine idling.

To perform the two pressure checks, it is necessary to connect a pressure gauge assembly into the hydraulic line

between the pump and steering gear.

PROCEDURE

1. Place a drain tray beneath the power steering pump assembly.

2. Loosen and remove the high pressure hydraulic line fitting and O-ring from the power steering pump.

3. Install pressure gauge assembly (Hose set AU392 and Gauge assem bly E1461-1) between the outlet fitting of

the pump and the high pressure hose fitting (1).

4. R efill system with f luid to the correct level, r efer to 3.1 FL UID LEVEL CHECK in this Section. Ensur e that there

are no leaks at either the hose or gauge connections.

5. Bleed air from the system , refer to 3.3 HYDRAULIC SYSTEM , BLEEDING/ REFILLING PROCEDURE, in this

Section.

Figure 9A-9

TEST 1 - HYDRA ULIC CIRCUIT OPEN

1. With valve open, start engine, allow to idle and with steering LIGHTLY on full lock, check connections for

leakage.

2. Insert thermometer into reservoir filler opening and move steering from lock to lock until fluid reaches 75°

Celsius.

3. Turn steering to full lock momentarily, if pressure is below 7,580 kPa (V6 engine) or 8,270 kPa (GEN III V8

engine), a faulty hydraulic circuit is indicated.

TEST 2 - HYDRAULIC CIRCUIT CLOSED

1. Slowly turn valve on Tool E1461-1 to the closed position, note pressure, and quickly re-open valve to avoid

pump damage.

2. If pressure was less than 7,580 kPa (V6 engine) or 8,270 kPa (GEN III V8 engine), the pump may be

considered to be faulty.

3. If pressure was between 7,580 - 8,270 kPa (V6 engine) or 8,270 - 8,960 kPa (GEN III V8 engine), steering gear,

external hoses or connections may be considered faulty.

NOTE: If pump proves faulty, retest after overhaul to check repairs and condition of steering gear.

4. At the completion of tests, remove pressure gauge, hoses and connectors.

5. Reinstall high pressure line and O-ring to the pump outlet fitting and tighten the flare nut to the correct torque

specification.

HIGH PRESSURE LINE FLARE NUT 25 - 35

TORQUE SPECIFICATION Nm

6. While LIGHTLY holding the steering wheel on full lock, have an observer check for fluid leaks from the hose

connections.

The following flow chart, details an alternative procedure for checking the power steering hydraulic system.

POWER STEERING HYDRAULIC SYSTEM CHECK

STEP ACTION YES NO

1 • Start engine and allow to idle.

• Is fluid level correct? Go to Step 2. Top up as required

and check for leaks.

Go to Step 2.

2 • Check fluid condition. Is fluid condition OK? Go to Step 3. Drain, flush system

and refill with fluid.

Go to Step 3.

3 • With valve on test gauge fully open, check pressure

reading.

• Is the pressure reading for standard power steering

approximately 350 kPa or:

• With speed sensitive power steering, is the pressure

reading approximately 700 kPa?

Go to Step 4. Check hoses/pipes for

restriction. Repair or

replace as necessary.

Go to Step 4.

4 • Is system pressure now to specification? Go to Step 5. Replace steering rack

valve assembly.

Go to Step 3.

5 • Close then open valve fully three times, noting the highest

pressure reading each time.

NOTE: Do not leave valve closed for more than five seconds,

as pump damage could result.

• Are all readings between 7,580 - 8,270 kPa (V6) or 8,270 -

8,960 kPa (V8) and within 340 kPa of each other?

Hydraulic system is

operating to

specification.

Go to Step 6.

6 • Are pressures within specified range but not within 340 kPa

of each other? Go to Step 7. Go to Step 9.

7 • Remove flow control valve and remove any burrs with

crocus cloth or fine hone.

• Repeat Step 4. Are pressure readings now OK?

Hydraulic system is

now operating to

specification.

Go to Step 8.

8 • Remove pump, disassemble clean, reassemble and

reinstall.

• Repeat Step 4. Are pressure readings now within 340 kPa

of each other?

Hydraulic system is

now operating to

specification.

Go to Step 10.

9 • Are pressures within 340 kPa of each other but below

specified maximum range? Go to Step 10. Go to Step 5.

10 • Replace flow control valve, then repeat Step 4.

• Are pressure readings now OK? Hydraulic system is

now operating to

specification.

Overhaul or replace

power steering pump.

Go to Step 5.

3.5 TIE ROD BALL JOINT

REPLACE

Tie rod ball joints are serviced as an assembly and

must be replaced when excessive up or down

movement is evident, or if any lost motion or end

play exists at the ball end of the stud.

1. Raise front of vehicle and place on safety

stands. Refer to Section 0A GENERAL

INFORMATION of the VT Series I Service

Information.

2. Remove front wheel cover (steel wheels) or

centre caps (alloy wheels)

3. Mark relationship of each wheel to hub/brake

disc. Remove road wheel attaching nuts and

remove wheels.

4. Remove split pin and nut from tie rod ball stud.

5. Using Tool No. 9A10 or similar, tighten centre

screw to force stud from taper in steering arm.

6. Loosen tie rod lock nut. Unscrew ball joint (1)

from tie rod, counting the number of turns to

wind ball joint from tie rod.

7. Install new ball joint (1) onto tie rod and wind on

the same number of turns as in Step 3.

8. Install ball joint to steering arm. Install

castellated nut and tighten to the correct torque

specification.

TIE ROD BALL JOINT STUD 50 - 85

TORQUE SPECIFICATION Nm

NOTE: Ensure that the nylon spacer is positioned

on the tie rod ball joint stud before installing into

steering arm.

9. Install new split pin into tie rod ball studs.

Figure 9A-10

10. Check front wheel toe. Refer to

Section 3 FRONT SUSPENSION of the VT

Series II Service Information.

NOTE: Ensure plastic spacers are positioned on tie

rod end ball studs and that they are in good condition

before fitting studs into steering arms. Replace

spacers if damaged.

11. Tighten the tie rod end lock nuts to the corrct

torque specifcation.

TIE ROD BALL JOINT LOCK NUT 50 – 85

TORQUE SPECIFICATION Nm

12. Install wheels, aligning marks made on removal.

Tighten wheel attaching nuts to the correct

torque specification. Do not over-tighten!

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

13. Lower vehicle to ground and reconnect battery

earth lead.

14. Check front wheel toe-in setting, refer to

Section 3, FRONT SUSPENSION of the VT

Series II Service Information for details

3.6 POWER STEERING GEAR

IMPORTANT: Remove the ignition key from the

ignition lock an d en sure t hat t he steering column

is locked. If this operation is not carried out and

the steering wheel is spun while the steering

gear is removed from the vehicle, the clock

spring coil in the upper end of the steering

column will be destroyed!

REMOVE

NOTE: While the illustrations for this service

operation show the single piece valve housing

steering gear, the procedure is also applicable to the

two-piece valve housing, f itted to the speed sensitive

steering rack.

1. Disconnect battery earth lead.

2. Raise front of vehicle and place on safety

stands. Refer to Section 0A GENERAL

INFORMATION of the VT Series I Service

Information.

3. Remove front wheel cover (steel wheels) or

centre caps (alloy wheels)

4. Mark relationship of each wheel to hub/brake

disc. Remove road wheel attaching nuts and

remove wheels.

5. Place a drain tray beneath steering gear.

6. Loosen and remove hydraulic lines (2 and 3)

from steering gear valve housing (1) and allow

fluid to drain into a suitable container.

Figure 9A-11

7. Remove steering coupling lower cam bolt nut

(4), then remove the cam bolt (2).

Figure 9A-12

Techline

8. Remove tie rod ball joint split pins and

castellated nuts (’3’ in Figure 9A-14).

9. Separate tie rod ball joint (1) studs from

steering arm tapers using a suitable remover,

such as Tool No. 9A10.

Figure 9A-13

10. Remove steering gear housing to front

suspension crossmember mounting bolts (1)

and nuts (2).

11. Remove steering gear by pulling it out from

front suspension crossmember mounting (4)

and slide pinion (input) shaft (5) from steering

coupling lower clamp.

Figure 9A-14

REINSTALL

1. Ensure steering gear is centralised.

NOTE 1: This is achieved by rotating the pinion to

the half way position of its total lock to lock r otation.

W hen the rac k is in the stra ight ahead position, the

pinion (input) shaft will be aligned as shown.

NOTE 2: Alternatively, remove both inner boot

clamps, slide the boots back and measure the

exposed portion of each end of the rack from the

housing. When both measurements are equal, the

rack is centralised.

2. Ensure steering wheel is in straight ahead

position.

3. Slide steering gear pinion (input) shaft into

steering coupling lower flange.

4. Position steering gear housing into

cross member mounting points. Ins tall mounting

bolts, washers and nuts and tighten nuts to the

correct torque specification.

STEERING GEAR HOUSING TO

CROSSMEMBER MOUNTING 70 - 85 Nm

TORQUE SPECIFICATION

5. Inspec t condition of steering gear hydr aulic line

O-rings. Replace as necessary.

Figure 9A-15

6. Refit hydraulic lines to steering gear valve

housing. Tighten flare nuts to the correct torque

specification.

HYDRAULIC LINE TO VALVE

HOUSING FLARE NUT 30 - 42 Nm

TORQUE SPECIFICATION

7. Install lower cam bolt (2) and a new nut (4).

Tighten to the correct torque specification.

STEERING COUPLING CAM BOLT 23 - 30

TORQUE SPECIFICATION Nm

8. Reinstall tie rod end ball studs into steering

arms. Reinstall castellated nuts and tighten to

the correct torque specification.

TIE ROD BALL JOINT STUD

CASTELLATED NUT 50 - 85 Nm

TORQUE SPECIFICATION

9. Install new split pins

NOTE: Ensure plastic spacers are positioned on tie

rod end ball studs and that they are in good

condition before fitting studs into steering arms.

Replace spacers if damaged.

10. Install wheels, aligning marks made on

removal. Tighten wheel attaching nuts to the

correct torque specification.

ROAD WHEEL ATTACHING NUT 110 - 140

TORQUE SPECIFICATION Nm

11. Lower vehicle to ground and reconnect battery

earth lead.

Figure 9A-16

12. Refill and bleed hydraulic system, refer

3.4, HYDRAULIC SYSTEM, BLEEDING/

REFILLING in this Section.

13. Check front wheel toe-in setting, refer to

Section 3, FRONT SUSPENSION of the VT

Series II Service Information for details.

DISASSEMBLE

For identification of components, refer to

Figure 9A-23.

1. Clean all dirt and foreign matter from exterior

of steering gear assembly.

2. Mount steering gear housing (1) by gripping

right hand mounting boss in a vice fitted with

soft jaws (2 ).

3. Place a drain tray beneath steering gear.

Figure 9A-17

4. Unclip and remove all bellows clips.

a. To remove outer clips (1): Move ends of

clips sideways until they disengage.

Figure 9A-18

b. To remove inner c lips (1): Push out the pin

retaining the clip ends together using a fine

pin punch.

Figure 9A-19

5. Loosen tie rod lock nuts (2). Remove tie rod

ball joints (3) and lock nuts (2) from tie rods (1).

6. Slide bellows from steering gear housing and

tie rods.

7. Rotate pinion (input) shaft fully counter-

clockwise (full left lock).

Figure 9A-20

Figure 9A-21 - Rack and Pinion Power Steering Gear

LEGEND

1. Cover - Dust

2. Circlip - Pinion Seal Retaining

3. Seal - Pinion Upper

4. Bearing - Pinion Upper Roller

5. Circlip

6. Valve Assembly - Rotary

7. Sealing Rings - 4 places

8. Seal - Pinion Intermediate

9. Bearing - Pinion Intermediate Roller

10. Bearing - Ball

11. Nut - Pinion

12. Plug - Sealing Screw

13. Insert - Rack Pad

14. Pad - Rack

15. Washer - Plastic

16. Spring

17. Plug - Rack Pad

18. Nut - Lock

19. Housing - Steering Gear

20. Pipe - Rack Piston Fluid - Short

21. Pipe - Rack Piston Fluid - Long

22. Rack and Piston Assembly

23. Spacer - Inner Rack Seal

24. Seal - Inner Rack

25. Sealing Ring - Rack Piston

26. O-ring - Rack Piston

27. Seal - Outer Rack

28. Bushing - Rack Outer

29. Wire - Retaining

30. Rod - Tie

31. End - Tie Rod

32. Nut - Lock

33. Clip - Bellows Outer

34. Bellows

35. Strap - Bellows Inner Tie

36. Bracket - Mounting

37. Insulator - Mounting Bracket

8. Remove steering gear housing from vice and

grip exposed tooth end of rack (1) in vice with

soft jaws (3 ).

9. Using Tool No. AU305, loosen then tighten tie

rod ball joint housing (2) to break the staking,

then unscrew housing from end of rack.

10. Remove housing assembly from vice and

ensure that there is no foreign matter on rack

teeth. Rotate pinion ( input) shaf t clock wise, jus t

enough to expose left hand tie rod ball joint

housing.

11. Remount steering gear in vice, again gripping

on the right hand end of the exposed teeth of

rack.

12. Remove left-hand tie rod assembly, using the

same method described in step 9.

Figure 9A-22

13. Remount s teer ing gear hous ing ( 3) in vice fitted

with protective jaws, gripping right-hand

mounting boss.

14. Disconnect feed pipes (1 and 4) from valve

housing (2) and steering gear tubing (3).

Figure 9A-23

15. Remove dust cover from valve housing and

input shaft.

Figure 9A-24

16. Using suitable circlip pliers, compress and

rem ove the pinion s eal r etaining c irc lip f r om the

top of the housing.

Figure 9A-25

17. Remove pinion lower bearing screw plug (1)

from housing (2).

Figure 9A-26

18. While holding the input pinion with a 15 m m set

spanner across the flats, remove pinion lower

bearing retaining nut from pinion, using a 17

mm socket and ratchet.

Figure 9A-27

19. Remove rack pad adjuster lock nut (1) using

Tool No. AU301.

20. Rotate input shaft fully clockwise (full right

lock).

Figure 9A-28

21. Loosen and remove rack pad adjuster screw

(1), using Tool No. AU211-A.

Figure 9A-29

22. Remove rack pad spring (1), plastic washer

and rack pad assembly from steering gear

housing.

NOTE: Snap ring pliers can be used to grasp the

rack pad inside the internal flange and twisting

back and forth while pulling to remove.

Alternatively, remove the housing f rom the vic e and

tap gently on a wooden block to dislodge the rack

pad assembly.

Figure 9A-30

23. With the steering gear housing supported on

suitable press plates such as J 22912-01 as

shown, use a suitable drift and press on the

lower end of pinion to remove pinion assembly

from housing.

NOTE: While pressing is the preferred method of

removing the pinion assembly from the housing, a

brass drift and hammer could also be use for this

operation. However, considerable f orce will need to

be applied to remove the pinion assem bly from the

lower ball bearing and housing as the upper pinion

seal and roller bearing are also removed in this

operation.

Figure 9A-31

24. Screw Tool 211-259 to driver handle AU355-A,

then insert tool assembly into the rack housing

and tap the lower pinion ball bearing from the

housing.

NOTE: As this oper ation will possibly brinell the ball

race, discard after removal.

Figure 9A-32

25. If required, remove the intermediate pinion

roller bearing and s eal by using a pin punch (1)

and hammer, working from opposite sides of

the bearing case until the bearing and seal are

dislodged from the housing

NOTE: As this operation will permanently damage

the roller bearing it must be replaced after removal.

Figure 9A-33

26. Remove and discard PTFE rings from rotary

valve outer sleeve.

The seals are best removed by cutting

diagonally with a sharp knife, but care must be

taken to avoid scratching the sides of the

grooves otherwise subsequent leakage will

result.

NOTE: Because of component matching that is

critical to the s afe oper ation of the sleeve and valve

assembly, THE PINION ASSEMBLY MUST NOT

BE FURTHER DISMANTLED.

Figure 9A-34

27. Using a white marker pen or similar, mark the

relative position of the left hand mounting

bracket and the steering rack tube (1).

Figure 9A-35

28. Remove the left hand mounting bracket, by

using a round bar inserted through the

mounting holes and rotating the bushing and

bracket, back and forth while pulling at the

same time.

Figure 9A-36

29. Remove the rack end bushing retaining wire,

as follows:

a. Using Tool No. E8803-7 with a socket

extension and bar, r otate the rack end bush

anti-clockwise, until the end of the retainer

(1) appears in the slot.

b. Carefully prise the end of the retainer wire

free of the rack tube as shown, then rotate

the end bus hing with Tool No, E8803-7, in a

clockwise direction (arrow), winding the

retainer out of the tube.

c. Continue unwinding the retainer until the

end of the retainer (1) appears, then lift it

from the slot in the rack tube.

Figure 9A-37

30. Support the tube end of the rack housing (2)

over suitable press plates such as J22919-01

or similar, the remove the rack from the

housing by inserting a brass drift (1) into the

right threaded end of the r ack and pr essing the

rack from the tube end of the rack housing.

NOTE: While a drift and hammer could also be

used, considerable resistance will be encountered,

as rack removal also removes the rack end bush

and the outer piston rod seal from the steering

tube.

Figure 9A-38

31. Insert a suitable length of tubing or mild steel

stock (1), 30 mm in diameter into the housing

from the pinion end, then use a hammer (or

press) to drive the spacer (2) and inner piston

rod seal (3) and from the rack housing.

Figure 9A-39

32. Remove rack piston seal (1) and O-ring (2)

from the rack piston.

NOTE: The seal (1) can be more easily removed

by cutting diagonally with a sharp knife, but take

care not to scratch the sides of the seal groove,

during this process.

Figure 9A-40

CLEAN AND INSPECT

Thoroughly wash all metal parts in cleaning solvent and blow dry with compressed air.

1. Inspect rubber bellows for damage or deterioration, replace if necessary.

2. Inspect pinion bearings for signs of brinelling, damage or wear.

NOTE: As the intermediate pinion bearing will have been damaged on removal and the lower ball bearing will

possibly have suffered brinelling damage, both of these bearings must be replaced on reassembly.

3. Inspect pinion for signs of tooth wear or damage.

4. Inspect rack for signs of wear or damage to teeth, rack pad faces and rack bearing journal.

NOTE: A light polish on teeth and rack rear face is normal and should not be confused with wear.

5. Inspect housing for wear or damage in pinion bearing bores, seal bores, rack piston and lock stop faces.

6. Inspect rack pad for damage or excessive wear.

7. Inspect major components of pinion assembly (pinion, valve, sleeve and torsion bar) for damage or wear.

NOTE: These parts cannot be serviced individually as they are hydraulically balanced at the pinning stage of

assembly to equalise the steering efforts in right and left directions.

REASSEMBLE

1. Check that each of the rack seals have a

circular , plastic insert ring f itted to each, on the

opposite side to the spr ing loaded seal lip, with

the tapered edge of the insert facing in toward

the seal. Ensure the tapered ends of the rings

seat correctly.

2. Screw Tool No. AU460 onto driver handle Tool

No. AU355-A with the O-ring end facing out.

Install the inner seal spacer (3) onto Tool No.

AU355-A, using the O- ring to hold the s pacer in

place. Insert the tools and spacer into the rack

tube.

3. Using tool combination AU460/AU355-A, press

the seal spacer (3) into the rack housing (1),

until the end of Tool No. AU355-A protrudes

from the rack tube by approximately 53 mm.

This measurement will ensure that the spacer

has been fully installed.

4. Reverse the fitment of Tool No. AU460 to the

driver handle Tool No. AU355-A.

5. Lubricate a new rack inner seal (2) with

Dexron® III autom atic transm ission fluid. Install

the seal (2) over the spigot of T ool No. AU460,

ensuring that the spring loaded sealing lip is

facing Tool No. AU460.

6. Press seal into the rack housing (1) on top of

the spacer (3). The seal will be fully installed

when the end of Tool No. AU355-A protrudes

from the rack tube by approximately 60 mm.

Figure 9A-41

7. Install a new O-ring to groove in rack piston.

8. After dipping a new Teflon seal ring in clean

power steering fluid, install the seal ring over

expander Tool No. E8803-9.

Figure 9A-42

9. With the seal ring still installed on Tool No.

E8803-9, slide the assembly over the rack and

up to the piston. Slide the seal ring (1) off the

expansion tool and into the piston groove (2),

over the O-ring.

Figure 9A-43

10. Ensure that the seal is seated correctly in the

groove, by wrapping f ingers around the seal, as

shown.

Figure 9A-44

11. Install protector sleeve, Tool No. AU456 over

the toothed end of the rack and liberally apply

clean power steering fluid to the protector’s

outer surface.

12. Liberally apply clean power steering fluid to the

inner surf ac e of the r ack tube and over the rack

piston seal.

13. Carefully install the rack and protector into the

rack housing and through the inner seal,

aligning the rack teeth with the pinion bore.

Continue installation until the rack piston has

entered the smaller, inner tube diameter.

Remove the seal protector, Tool No. AU456

from the toothed end of the rack.

Figure 9A-45

14. Install the shorter seal protector E8803-6 over

the end of the rack, at the plain end.

Liberally apply clean power steering fluid to the

lip surface of the outer rack seal (1), then install

over the protector and onto the rack, with the

seal lips facing in towards the rack piston.

Figure 9A-46

15. Lubricate the left hand end bearing (1), inner

surface, with clean power steering fluid, then

install into the rack tube, pushing in against the

outer rack seal.

NOTE: To assist in installation of the bearing

retaining wire, align the hole in the bearing with the

opening in the steering housing tube.

16. Using installer Tool No. E8803-11, install the

outer seal and bearing until the retaining wire

groove is aligned with the slot in the rack

housing tubing.

Figure 9A-47

17. If necessary, rotate the end bearing with Tool

No. E8803-7, until the hole in the wire groove

appears in the tube slot.

Install the bent end of the bearing retaining

wire, into the hole then, continuing to use Tool

No. E8803-7, rotate the bearing in an anti-

clockwise direction until the end of the wire

disappears into the rack tubing.

Figure 9A-48

18. Install Tool No. E8803-10, to the two cylinder

pipe fittings. Tighten the unions just enough to

effect an air tight seal.

19. Using a hand vacuum pump, such as T ool No.

J-23738-A, apply a vacuum of 53.3 kPa (or 40

cm, 15.75 in. Hg), for approximately 30

seconds.

20. Check that no change in the vacuum occurs

during this period. If a c hange does occ ur, then

the reas on m ust be f ound and correc ted befor e

proceeding further.

Figure 9A-49

21. Check the mounting bracket insulator for

serviceability. Apply petroleum j elly (Vaseline or

equivalent) to the inner surface, then install

bracket and insulator to the steering tube, in

the reverse manner to removal. Align the

marks mark prior to re moval.

Figure 9A-50

22. Centralise the rack assembly by measuring

82 ± 1 mm from the lock stop (flange inside

rack housing) to the end of the toothed rack

(1), as shown.

Figure 9A-51

23. Lubricate a new pinion intermediate roller

bearing (1) with Dexronâ III automatic

transmission fluid, then install on the longer

pilot of Tool AU527 that has driver handle

AU355-A attached.

24. Press the bearing (1) into the steering rack

housing until fully seated. Remove the

installation tools.

Figure 9A-52

25. Reverse Tool AU527 onto driver handle

AU355-A, then install a new intermediate seal

(1) onto the shorter pilot, with the seal lips

facing the tool shoulder.

26. Press the seal (1) into the steering rack

housing until fully seated. Remove the

installation tools.

Figure 9A-53

27. To fit new PTFE seal rings (1) to sleeve

grooves, first warm in hot water then install on

expander, Tool No. 9A23.

Slide expanding tool with ring installed, over the

sleeve, then push the seal off and into the

sleeve groove. Repeat for remaining three

seals.

Figure 9A-54

28. After all seals have been fitted to the sleeve

grooves, push Tool No. AU440 over rings and

valve assembly (1), then leave for 5-10 m inutes

to contract rings back to normal size.

Figure 9A-55

29. Inser t 50 gram s of EP Sem i Fluid Lithium Base

O Grease into the steering gear housing,

through the pinion bore.

30. While maintaining rack in centralised position,

insert pinion so that the clamp bolt flat of input

shaft is positioned as shown, when pinion is

fully located in housing.

Figure 9A-56

31. Pack pinion lower bearing with EP Semi Fluid

Lithium Base O Grease.

32. Reinstall pinion lower bearing, using the

following procedure:

a. Install a new, lubricated ball bearing over

the lower end of the pinion, then thread T ool

AU307 onto the pinion end.

b. While holding the knurled section with one

hand as shown, fit an 15 m m set spanner to

the flat section of the pinion (1) and turn

back and forth, advancing the installation

tool until the bearing is fully seated.

c. The bearing will be fully installed when Tool

AU307 cannot be advanced any further.

d. Remove AU307 when bearing is installed.

Figure 9A-57

33. Install pinion lower bearing retaining nut and

tighten to the correc t torque specif ication, using

a torque wrench and socket on the nut and a

15 mm set spanner holding the pinion input

shaft.

PINION LOWER BEARING

RETAINING NUT 35 - 45 Nm

TORQUE SPECIFICATION

NOTE: This nut has a deformed thread and may be

reused once only. However, it is strongly

recommended that a new nut is fitted at each

overhaul.

Figure 9A-58

34. Lubricate the upper pinion roller bearing (1)

with Dexronâ III automatic transmission fluid,

then install over the pinion shaft.

35. Reinstall the upper bearing (1) into the steering

rack housing, using Tool AU528 and a plastic

hammer.

NOTE: Tool AU528 s hould be used with the longer

shank facing the bearing. When the shoulder

contacts the rack housing, the bearing will have

been installed to the correct depth.

Figure 9A-59

36. Lubricate a new pinion shaft upper oil seal (1)

with Dexronâ III automatic transmission fluid,

then install over the pinion shaft with the seal

lips facing down.

37. Reinstall the pinion shaft upper oil seal (1) into

the steering rack housing, using Tool AU528

and a plastic hammer.

NOTE: Tool AU528 should be used with the shorter

shank facing the oil seal. When the shoulder

contacts the rack housing, the oil seal will have

been installed to the correct depth.

Figure 9A-60

38. Using suitable circlip pliers, reinstall the circlip

over the top of the pinion upper oil seal,

ensuring that the circlip locates correctly in the

housing groove.

Figure 9A-61

39. Apply Loctite 242 thread sealant (or equivalent

to Holden’s Specification HN1256) to the

cleaned threads of the pinion lower screw plug

(1), reinstall the plug into the housing (2) and

tighten to the correct torque specification.

PINION LOWER RETAINING

SCREW PLUG 55 - 60 Nm

TORQUE SPECIFICATION

Figure 9A-62

40. Reinstall rack pad insert to rack pad (if

rem oved). Reinstall rack pad assem bly into the

steering gear housing.

41. Reinstall plastic washer ( 1) and r ac k pad spring

(2).

Figure 9A-63

42. Screw lock nut onto adjusting screw. Install

adjusting screw (1) into steering gear housing,

using Tool AU211-A but leave the lock nut

loose.

Figure 9A-64

43. With steering rack in centralised position,

tighten rac k pad adj usting screw (2) us ing Tool

No. AU211-A, socket (1) and torque wrench to

the correct initial torque.

RACK PAD ADJUSTING

SCREW INITIAL 10 - 12 Nm

TORQUE SPECIFICATION

Figure 9A-65

44. Using angle wrench, Tools E7115 and AU211-

A, turn rack pad adjusting screw back (anti-

clockwise) 20 - 28°.

Figure 9A-66

45. Install Tool AU316 to input shaft and measure

rotating torque of input shaft, using a dial type

torque wrench such as J25765-A, by cycling

the steering gear back and forth. Torque

requirements are from 0.8 to 2.5 Nm.

46. As required, minor variations in rotating torque

from specification can be corrected by

readjusting the rack pad spring tension.

NOTE: If a large variation in rotating torque from

specification or binding is experienced, the cause

must be determined and corrected before

proceeding further.

Figure 9A-67

47. Apply Loctite 242 thread sealant (or equivalent

to Holden’s Specification HN1256) to the

cleaned threads of the rack pad plug lock nut.

48. While holding adjusting screw in the correctly

adjusted position with Tool No. AU211- A and a

socket bar, tighten the lock nut (1) to the

correct torque specification using Tool No.

AU301 and a torque wrench.

RACK PAD ADJUSTING

SCREW L OCK NUT 55 - 65 Nm

TORQUE SPECIFICATION

NOTE: Once the r ack pad adjus tment has been set

and the lock nut torqued to specification, the

steering gear must be racked from lock-to-lock to

ensure localised wear has not appreciably affected

the setting. The gear should not bind or appear

tight over any part of the total travel. Should gear

bind or appear tight, recheck rack pad adjustment.

If this is not the cause, strip gear assembly and

examine rack and pinion for wear. Replace as

necessary.

Figure 9A-68

49. Reconnect feed pipes (1 and 4) to valve

housing (2) and steering gear tubing (3) and

tighten pipe flare nuts to the correct torque

specification.

FEED PIPE FLARE NUT 15 - 25

TORQUE SPECIFICATION Nm

NOTE: The longer of the two pipes (LH lock) is

installed into the upper location on the valve body

housing, while the s horter ( RH lock ) is installed into

the lower.

Figure 9A-69

50. Rotate pinion shaft fully anti-clockwise (left

lock).

51. Remove steering gear housing from vice, and

grip exposed toothed end of rack in vice with

soft jaws.

52. Using Tool No. AU305, tighten right-hand tie

rod to the correct torque specification.

TIE ROD TO RACK 90 - 100

TORQUE SPECIFICATION Nm

53. Using c entre punch and ham mer, stake rac k to

tie rod ball joint housing.

54. Remove steering gear housing from vice and

rotate pinion shaft slightly clockwise, just

enough to expose the left hand end of rack.

55. Tighten left hand tie rod as in steps 53 and 54.

56. Relocate steering gear housing in vice by

gripping right hand mounting boss.

57. Rotate input shaft to straight ahead position.

Install dust cover onto input shaft.

Figure 9A-70

58. Reinstall a new dust cover to the pinion shaft,

ensuring that the cover is engaged with the

groove in the pinion.

Figure 9A-71

59. Refit bellows to tie rods and steering gear

housing. Reinstall retaining clips.

60. Refit tie rod ball joint lock nuts and tie rod ball

joints to tie rods.

NOTE: Do not tighten lock nuts, as toe adjustment

must be performed after steering gear is

reinstalled.

61. Reinstall steering gear assembly into the

vehicle, as detailed In 3.6 POW ER STEERING

GEAR - REINSTALL in this Section.

3.7 FLUID RESERVOIR - GEN III V8 ENGINE

REMOVE

1. Disconnect battery earth lead from the battery.

2. Remove the engine trim cover retaining nuts

(2) then remove the cover (1) from the engine.

Figure 9A-72

3. Place a drain tray beneath reservoir assembly.

4. Loosen hose clamps and remove the two

hoses from the reservoir.

NOTE: Cover or tape the hose ends to prevent

contamination ingress.

Figure 9A-73

5. Using a suitable lever such as a screwdriver

(1), gently lever locking tang back to clear the

reservoir tab, then lift the reservoir up and out

of the retaining bracket.

6. Reset the bracket locking tang back into the

original position.

7. If required, remove the two bolts securing the

com bination res ervoir and engine lif ting brack et

from the left hand cylinder head. Remove the

bracket from the engine.

Figure 9A-74

REINSTALL

Reinstallation is the reverse to removal operations, noting the following points:

1. If removed, reinstall the reservoir/engine lift bracket bolts and tighten to the correct torque specification.

RESERVOIR/ENGINE LIFT

BRACKET ATTACHING BOLT 50 Nm

TORQUE SPECIFICATION

2. Tighten reservoir hose clamps to the correct torque specification.

POWER STEERING RESERVOIR

HOSE CLAMP 2.0 - 3.0 Nm

TORQUE SPECIFICATION

3. Reinstall the engine trim cover, install the retaining nuts and tighten to the correct torque specification.

ENGINE TRIM COVER NUT 8.0 – 12.0

TORQUE SPECIFICATION Nm

4. Refill and bleed the hydraulic system. Refer to 3.4 HYDRAULIC SYSTEM - BLEEDING/REFILLING in this

Section.

5. Start the engine and check for fluid leaks from the reservoir area.

3.8 POWER STEERING PUMP - GEN III V8 ENGINE

REMOVE

6. Loosen the two hose clamps securing the air

intake duc t (3) to the throttle body and Mass Air

Flow (MAF) sensor.

7. Remove the air intake duct from the throttle

body and MAF sensor.

8. Rem ove the engine acces sory drive belt. Refer

to Section 6A3 - GEN III V8 ENGINE,

2.6 ENGINE DRIVE BELT S, of the VT Ser ies II

Service Information for the required procedure.

Figure 9A-75

9. Place a drain tray beneath power steering

pump assembly.

10. Remove the power steering fluid reservoir.

Refer 3.7 FLUID RESERVOIR - GEN III V8

ENGINE, in this Section.

11. Loos en and rem ove high pres sure line f lare nut

(1) and O-ring (2) from pump outlet fitting.

12. Loosen low pressure hose clamp (3) and

remove hose from pump inlet fitting.

NOTE: Cover or tape the pum p and hose fittings to

prevent dirt entry.

Figure 9A-76

13. Rem o ve the two power steering pum p retaining

bolts (2) securing the pump to the front of the

left hand cylinder head. Remove the pump

from the engine.

NOTE: Access to the two bolts can be made

through the pulley holes, using a suitable socket

and extension.

Figure 9A-77

REINSTALL

Reinstallation of the power steering pump is the reverse of removal procedures, noting the following points:

1. Tighten the two pump to cy linder head retaining bolts to the correct torque specification.

PUMP TO CYLINDER HEAD BOLT 20 - 35

TORQUE SPECIFICATION Nm

2. Install new sealing O-ring to high pressure line connection. Lubricate sealing ring with Dexron® III automatic

transmission fluid prior to installation.

3. Tighten the high pressure pipe flare nut to pump outlet fitting, to the correct torque specification, using a back-

up spanner on the outlet fitting.

HIGH PRESSURE LINE FLARE NUT 25 - 35

TORQUE SPECIFICATION Nm

4. Reinstall and tighten all low pressure hose clamps to the correct torque specification.

LOW PRESSURE HOSE CLAMP 2.0 - 3.0

TORQUE SPECIFICATION Nm

5. Reinstall power steering pump fluid reservoir. Refer 3.7 FLUID RESERVOIR - GEN III V8 ENGINE, in this

Section.

6. Reinstall engine accessory drive belt. Refer to Section 6A3 GEN III V8 ENGINE, 2.6 ENGINE DRIVE BELTS, of

the VT Series II Service Information for the required procedure.

7. Reinstall air intake duct to the throttle body and MAF sensor and tighten the hose c lamps to the cor rect torque

specification.

AIR INTAKE DUCT HOSE CLAMP 5.0 - 8.0

TORQUE SPECIFICATION Nm

8. Reinstall the engine trim cover, install the retaining nuts and tighten to the correct torque specification.

ENGINE TRIM COVER NUT 8.0 - 12.0

TORQUE SPECIFICATION Nm

9. Refill and bleed hydraulic system, refer to 3.4 HYDRAULIC SYSTEM - BLEEDING/REFILLING in this Section.

10. Start engine and check for fluid leaks around pump and reservoir area.

OVERHAUL PROCEDURES

Refer to 3.8 POWER STEERING PUMP - V6 ENGINE, of the VT Series I Service Information for the necessary

procedures to disassemble, clean and inspect and reassemble the power steering pump fitted to the GEN III V8

engine.

3.9 POWER STEERING PUMP PULLEY - GEN III V8 ENGINE – METHOD 1

REPLACE – USING TOOL AU188 & E9239A

1. Remove power steering pump, refer to

3.8 POWER STEERING PUMP GEN III V8

ENGINE in this Section.

2. Install s uitable pr ess plates , suc h as J22912-01

under the power steering pump pulley (1) with

pulley press plates, Tool AU188 in between the

two and press pump assembly (2) from pulley,

using a suitable sized drift on the pump pulley

shaft.

NOTE: Do not position pr ess plates on the edge of

the pulley, as damage to the pulley will occur.

Figure 9A-78

3. Ensure pulley bore and pump pulley shaft are

free of burrs, place pulley on end of pump

shaft.

4. Install Tool No. E9239A (or J25033-B) by

screwing bolt fully into pump pulley shaft.

5. Reinstall pulley by holding the bolt head and

turning the large nut and bearing clockwise

until pulley is flush with shaft end.

6. Remove Tool No. E9239A (or J25033-B).

7. Reinstall the power steering pump, refer to

3.8 POWER STEERING PUMP – GEN III V8

ENGINE, in this Section.

Figure 9A-79

3.10 POWER STEERING PUMP PULLEY - GEN III V8 ENGINE – METHOD 2

REPLACE – USING 7185 – POWER STEERING PULLEY REMOVER & 7005 – POWER STEERING PULLY

INSTALLER

1. Remove power steering pump, refer to

3.8 POWER STEERING PUMP GEN III V8

ENGINE in this Section.

2. Lubricate the forcing screw (1) of 7185 –

POWER STEERING PULLEY REMOVER and

position the forcing screw against the pulley

shaft.

NOTE: Ensure the full diameter end of the half

jaws (2) are engaged with the pulley (4) and the

larger open end diameter (has chamfer and relief

profile) engages with the pulley flange.

3. Slide the retainer sleeve (3) over the half jaws

and hand tighten the forcing screw. Ensure

forcing screw is aligned with the pump axis.

4. Proceed to remove the pulley.

NOTE: Do not use power tools or exceed a torque

of 90Nm . If the pully cannot be removed within this

torque, replace the complete pump assembly.

Figure 9A-80

5. Assemble the drive nut (1), thread insert (2)

onto the forcing screw of 7005 – POWER

STEERING PULLEY REPLACER as shown in

fig 9.80. Ensure adequate graphite grease is

applied to the forcing screw and nut.

6. Thread the forcing screw assembly, by hand

onto the pump shaft (5) until it bottoms out

against the shoulder. DO NOT USE A

SPANNER FOR THIS OPERATION.

7. T ur n the drive nut ( 1) against the pulley (3) until

the pulley is at the correct installation depth.

DO NOT ALLOW THE FORCING SCREW TO

TURN DURING THIS OPERATION.

NOTE: Do not use power tools or exceed a torque

of 90Nm. If the pully cannot be installed within this

torque, replace the complete pump assembly.

8. Onc e the pulley is installed, rem ove the forc ing

screw from the pump shaft.

9. Reinstall the power steering pump, refer to

3.8 POWER STEERING PUMP – GEN III V8

ENGINE, in this Section.

Figure 9A-81

Techline

3.11 OIL COOLER AND HOSE/PIPE ROUTING - GEN III V8 ENGINE

ARRANGEMENT

Refer to Figures 9A-82 and 9A-83 for the general arrangement of the power steering oil cooler, hoses, pipes and

fittings used for the power steering system fitted to vehicles with the GEN III V8 engine. Torque specifications are

also provided.

Legend for Figure 9A-82

1. Rack - Steering

2. O-ring - Fluid Pipe to Steering Rack

3. Flare Nut - Fluid Pipe (2 places)

4. Pipe - Steering Rack to Fluid Cooler

5. Pipe - Steering Rack to Pump

6. Clamp - Low Pressure Hose

7. Hose - Low Pressure

8. O-ring - Fluid Pipe to Pump

9. Flare Nut - Fluid Pipe

10. Hose - Low pressure to Reservoir

11. Screw - Low Pressure Pipe Bracket

12. Clamp Low Pressure Hose

13. Pipe - Fluid Cooler to Reservoir

14. Screw - Low Pressure Pipe Bracket

15. Reservoir - Fluid

16. Clamp - Low Pressure Hose

17. Bolt - Pipe to Oil Pan Bracket

Figure 9A-82 - GEN III V8 Engine - Power Steering Hose/Pipe Routing

Figure 9A-83 - GEN III V8 Engine - Power Steering Fluid Cooler Hose/Pipe Routing

Legend

1. Screw - Hose Bracket

2. Hose - Fluid Cooler to Steering Rack

3. Cooler - Fluid

4. Clamp - Worm Drive Hose (4 places)

5. Hose - Fluid Cooler to Fluid Reservoir

6. Pipe - Power Steering Rack

7. Pipe - To Fluid Reservoir

8. Screw - Cooler Bracket

9. Screw - Fluid Cooler (2 places)

4. DIAGNOSIS

4.1 GENERAL DIAGNOSTIC INFORMATION

Faulty steering can be caused by problems in areas other than the pump or steering gear. Areas of the steering

system that can be easily checked and quickly corrected without disassembly and overhaul of any major

components, should be attempted first.

Problem s suc h as hard or loose st eering, road shoc k or vibrations are not always due to the steering gear or pump,

but are often related instead to such factors as low tyre pressure or front end alignment. These items should be

checked and corrected before any adjustment or disassembly of the steering gear or pump is attempted.

Other factors that may affect correct operation of the steering system, are:

1. Loose component mountings.

2. Drive belt tension.

3. Fluid level and condition.

These factors must be checked and corrected before making any further diagnosis of the steering system.

After the source of the problem has been located, the cause of the problem can be diagnosed and corrected.

For exam ple, if the fluid level in the reser voir is found to be low, ref ill and check the entire hydraulic system for fluid

leaks. Refilling the reservoir will not necessarily correct the problem.

Techline

4.2 POWER STEERING PUMP

DIAGNOSTIC ITEMS

Chirp Noise In Steering Pump.

1. Incorrectly tensioned drive belt.

Drive Belt Squeal (Particularly noticeable at full wheel travel and standstill parking).

1. Incorrectly tensioned drive belt.

Growl Noise In Steering Pump.

1. Excessive back-pressure in hoses or steering gear caused by restriction of flow.

Growl Noise In Steering Pump (Particularly noticeable at standstill parking).

1. Scored pressure plate, thrust plate or rotor.

2. Extreme wear of pump ring and vanes.

Groan Noise In Steering Pump.

1. Low fluid level.

2. Air in the fluid. Poor pressure hose connection.

Rattle Noise In Steering Pump.

1. Vanes not installed correctly.

Momentary Increase In Effort When Turning Wheel Fast To Right Or Left.

1. Low fluid level.

2. Drive belt slipping.

3. High internal leakage.

Steering Wheel Surges Or Jerks When Turning With Engine Running, Especially During Parking.

1. Low fluid level.

2. Incorrectly tensioned drive belt.

3. Insufficient pump pressure.

4. Sticky flow control valve.

Hard Steering Or Lack Of Assist, Especially In Parking.

1. Incorrectly tensioned drive belt.

2. Low fluid level.

3. Steering gear to column misalignment.

4. Tyres not properly inflated.

NOTE: If rectification of checks 1 through 4 does not correct hard steering, follow the Power Steering Test

Procedure as outlined in 3.4 HYDRAULIC SYSTEM CHECK in this Section.

Further possible causes could be:

5. Sticky flow control valve.

6. Insufficient pump pressure output.

7. Excessive internal pump leakage.

8. Excessive internal system leakage.

Foaming or Milky Power Steering Fluid, Low Fluid Level And Possible Low Pressure.

1. Air in the fluid, and loss of fluid due to internal pump leakage, causing overflow.

Low Pressure From Steering Pump.

1. Flow control valve stuck or inoperative.

2. Pressure plate not flat against pump ring.

3. Extreme wear of pump ring and vanes.

4. Scored pressure plate, thrust plate or rotor.

5. Vanes not installed correctly.

6. Vanes sticking in rotor slots.

7. Cracked or broken thrust or pressure plate.

8. High internal leakage.

LEAK DIAGNOSIS

General Procedure

1. Wipe suspected area dry.

2. Check for overfilled reservoir.

3. Check for aeration and overflow of foaming fluid.

4. Check hose connections - tighten if necessary to the specified torque.

5. Verify exact point of leakage.

Example: The location the fluid drips from is not neces sarily the leakage point - f luid could be overflowing from the

reservoir (V8) for example.

6. When service is required:

a. Clean leakage area upon disassembly.

b. Replace leaking seal.

c. Check component sealing surfaces for damage and replace component if necessary.

d. Tighten fastener/s to the specified torque where required.

External Leakage Check

The purpose of this procedure is to pinpoint the location of the leak. In som e cas es, the leak c an easily be located.

Seepage type leaks may be more difficult to isolate. To locate seepage leaks, use the following method.

1. With the engine stopped, wipe the complete power steering system dry (steering gear, pump, hoses and

connections).

2. Check the fluid level in the pump’s reservoir. Add fluid if necessary.

3. Start the engine then turn the steering wheel from stop to stop several times. Do not hold it at a stop for any

length of tim e, as this can dam age the power steering pum p. It is easier if s omeone else operates the steering

wheel while you search for the seepage.

4. Find the exact area of the leak. If the leak is in the steering gear assembly, remove and repair as necessary .

Seal Replacement Recommendations

Lip seals, which s eal rotating shafts , require special tr eatment. T his type of seal is used on the steering gear pinion

shaft and on the dr ive s haf t of the pump. When there is a leak in one of thes e areas , always replace the seal/s af ter

inspecting and thoroughly cleaning the sealing s urfaces . Replace the shaf t only if very severe pitting is f ound. If the

corros ion in the lip seal c ontac t area is s light, clean the s urf ac e of the s haf t with crocus cloth. Replace the shaft only

if the leakage cannot be stopped by first smoothing with crocus cloth.

Pump Leak Diagnosis

NOTE: The following explanations relate to the

numbers shown in Figure 9A-84.

1. Replace drive shaft seal. Make certain that

drive shaft is clean and free of pitting in seal

area.

2. Torque high pressure pipe flare nut to 25 - 35

Nm. If leakage persists, replace O-ring seal.

3. Torque outlet fitting to 50 - 102 Nm. If leakage

persists, replace O-ring seal.

4. Replace end plate O-ring seal.

Figure 9A-84

5. SPECIFICATIONS

STEERING GEAR

Steering Gear Type

Power Steering................................................... Rack and pinion with integral power cylinder and

rotary valve mechanism - variable ratio

Steering Gear Ratio

On-centre........................................................... 17.2:1

Toward Lock ...................................................... 11.8:1

No. of Steering Wheel turns Lock to Lock .............. 3.0

Nominal Rack Travel Total...................................... 164 mm

POWER STEERING

Make ....................................................................... Saginaw

Type

GEN III V8 Engine............................................ ‘N’ Series droop flow vane type

Pressure at 1,000 engine rpm

GEN III V8 Engine............................................ 8,270 - 8,960 kPa

Drive........................................................................ Pulley

Lubrication (Power Steering)

Hydraulic ............................................................ Dexron® III Automatic Transmission Fluid

Fluid Capacity..................................................... Approx. 650 ml

Note: Use fluid level indicator as a final check

to ensure correct refill quantity

Drive Belt Tension

GEN III V8 Engine............................................ Belt Self Adjusting

FRONT WHEEL TOE

Front Toe-in (Degrees Total) ............................. 0° 10’ ± 0° 10’

Front Toe-in (Degrees per Wheel)..................... 0° 5’ ± 0° 5’

LUBRICANTS

Specified Grease..................................................... EP Semi Fluid Lithium Base O Grease

SEALANTS

Specified Locations................................................. Loctite 242 or equivalent, to Holden’s Specification

HN1256 Class 2, Type 2

6. TORQUE WRENCH SPECIFICATIONS

POWER STEERING GEAR

Hydraulic pipe to valve housing flare nut.............................. 30 - 42

Pinion lower bearing retaining nut ........................................ 35 - 45

Pinion lower bearing screw plug........................................... 55 - 60

Rack pad adjusting screw..................................................... 10 - 12, then back off 20 - 28°

Rack pad adjusting screw lock nut....................................... 55 - 65

Road wheel attaching nut ..................................................... 110 - 140

Steering coupling cam bolt nut ............................................. 23 - 30

Steering gear housing to crossmember mounting nut.......... 70 - 85

Steering rack feed pipe flare nut........................................... 15 - 25

Tie rod ball joint adjustment lock nut.................................... 50 - 85

Tie rod ball joint stud castellated nut .................................... 50 - 85

Tie rod to rack....................................................................... 90 - 100

GEN III V8 ENGINE POWER STEERING PUMP

Air intake duct hose clamp ................................................... 5.0 - 8.0

Engine dress cover nut......................................................... 8.0 - 12.0

High pressure hose flare nut ................................................ 25 - 35

Low pressure hose clamp - All ............................................. 2.0 - 3.0

Power steering pump outlet fitting ........................................ 50 - 102

Pump to right hand cy linder head bolt.................................. 20 - 35

Reservoir bracket mounting bolts......................................... 50

7. SPECIAL TOOLS

TOOL No. REF.

IN TEXT TOOL DESCRIPTION COMMENTS

211-259 LOWER PINION BEARING REMOVER

New release.

Used in conjunction with Driver

Handle AU355-A.

9A10 STEERING LINKAGE BALL STUD

REMOVER

Previously released for ‘V’ car

9A23 EXPANDER - SLEEVE SEALS

Previously released for HQ/WB

Series vehicles.

AU188 PRESS PLATES

Previously released for ‘J’ car.

AU211-A RACK PAD ADJUSTING SCREW WRENCH Previously released for ‘J’ car,

Manual Steering.

TOOL No. REF.

IN TEXT TOOL DESCRIPTION COMMENTS

AU301 RACK PAD ADJUSTING SCREW LOCK

NUT WRENCH Previously released for ‘V’ car.

AU305 TIE ROD WRENCH

Previously released for ‘V’ car.

AU307 LOWER PINION BEARING INSTALLER

Previously released for ‘VP’

Series.

AU316 PRE-LOAD ADAPTOR

Previously released for ‘VP’

Series.

AU355-A DRIVER HANDLE

Previously released as KM523-

1 for ‘J’ series transaxle.

Used in conjunction with AU306

and AU315.

TOOL No. REF.

IN TEXT TOOL DESCRIPTION COMMENTS

AU392 PRESSURE HOSE SET Previously released.

Comprises:

AU392-1, hose with male end

fitting.

AU392-2, hose with female end

fitting.

AU440 CONTRACTOR - SLEEVE SEALS Previously released for ‘VR’

Series, speed sensitive

steering.

AU456 RACK SEAL PROTECTOR - LONG New release.

AU460 INSTALLER - INNER RACK SEAL AND

SPACER Previously released.

Used in conjunction with Driver

Handle AU355-A.

AU527 INTERMEDIATE PINION BEARING AND

OIL SEAL INSTALLER

New release.

Used in conjunction with Driver

Handle AU355-A.

TOOL NO. REF

IN TEXT TOOL DESCRIPTION COMMENTS

AU528 UPPER PINION BEARING AND OIL SEAL

INSTALLER

New release.

E1461-1 PRESSURE GAUGE ASSEMBLY

Previously released as J22912-

E7115 ANGLE WRENCH

Previously released as KM470

for ‘V’ and ‘J’ cars.

E8803-6 RACK SEAL PROTECTOR - SHORT New release.

E8803-7 RACK PISTON TOOL New release.

Used to rotate the end bushing

to remove/install retaining wire

clip.

TOOL NO. REF

IN TEXT TOOL DESCRIPTION COMMENTS

E8803-9 RACK PISTON SEAL EXPANDER New release.

Used to expand the rack piston

seal prior to installation.

E8803-10 RACK SEAL TEST ADAPTOR

New release.

Used in conjunction with hand

vacuum pump to assess rack

seal serviceability.

E8803-11 RACK END SEAL/BUSH INSTALLER New release.

Used to install rack end seal

and bush.

E9239A POWER STEERING PUMP PULLEY

INSTALLER

Previously released as J25033-

B for ‘J’ and ‘V’ cars.

J22912-01 PRESS PLATES

Previously released.

TOOL NO. REF

IN TEXT TOOL DESCRIPTION COMMENTS

J23738-A HAND VACUUM PUMP Previously released or use

commercially available

equivalent.

J25765-A DIAL TYPE TORQUE WRENCH

Previously released for ‘LB’

Astra (transaxle), or use

commercially available

equivalent, capable of

measuring from 0.4 - 6.0 Nm.

7005 POWER STEERING PUMP PULLEY

INSTALLER

7185 POWER STEERING PUMP PULLEY

REMOVER