SECTION 9 - STEERING

IMPORTANT

Before performing any Service Operation or other procedure described in this Section, refer to Section 00,

CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.

CONTENTS

1. GENERAL INFORMATION

1.1 GENERAL DESCRIPTION - POWER

STEERING RACK AND PINION

PRINCIPLES OF OPERATION

POWER STEERING FLUID FLOW

1.2 GENERAL DESCRIPTION - POWER

STEERING PUMP

PUMP CONSTRUCTION

CONSTANT FLOW CONTROL VALVE

OPERATION

DROOP FLOW CONTROL VALVE

OPERATION

1.3 GENERAL DESCRIPTION - STEERING

COLUMN

2. STEERING COLUMN ASSEMBLY

SERVICE OPERATIONS

2.1 STEERING COLUMN ASSEMBLY

SERVICE NOTES AND PRECAUTIONS

CAUTIONARY NOTES

2.2 OCCUPANT PROTECTION SYSTEM

DISABLING AND ENABLING

PROCEDURE

2.3 HORN BAR AND DRIVER’S AIRBAG

2.4 STEERING WHEEL ASSEMBLY

REMOVE

REINSTALL

2.5 IGNITION BARREL LOCK CYLINDER

REMOVE

REINSTAL

2.6 IGNITION SWITCH

REMOVE

TESTING SWITCH

REINSTALL

2.7 STEERING LOCK

2.8 STEERING COLUMN UPPER BEARING

2.9 STEERING COLUMN ASSEMBLY

REMOVE

REINSTALL

CENTRING THE CLOCK SPRING COIL

2.10 CHECKING STEERING COLUMN FOR

ACCIDENT DAMAGE

2.11 TILT/REACH HANDLE

REPLACE

2.12 STEERING COLUMN LOWER BEARING

ASSEMBLY

2.13 STEERING COUPLING

3. POWER STEERING SERVICE

OPERATIONS

3.1 POWER STEERING FLUID LEVEL

CHECK

V6 ENGINE

GEN III V8 ENGINE

3.2 DRIVE BELT ADJUSTMENT

V6 ENGINE

GEN III V8 ENGINE

3.3 HYDRAULIC SYSTEM, BLEEDING/

REFILLING PROCEDURE

CAUTIONARY NOTES

BLEEDING/REFILLING PROCEDURE

3.4 HYDRAULIC SYSTEM, CHECK

PROCEDURE

3.5 TIE ROD SOCKET

REPLACE

3.6 RIGHT-HAND DRIVE POWER STEERING

GEAR

REMOVE

REINSTALL

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

3.7 LEFT-HAND DRIVE POWER STEERING

GEAR

REMOVE

REINSTALL

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

3.8 POWER STEERING FLUID RESERVOIR

- V6 ENGINE

REMOVE

REINSTALL

3.9 POWER STEERING FLUID RESERVOIR -

GEN III V8 ENGINE

REMOVE

REINSTALL

3.10 POWER STEERING PUMP - V6 ENGINE

REMOVE

REINSTALL

DISASSEMBLE

CLEAN AND INSPECT

REASSEMBLE

3.11 POWER STEERING PUMP- GEN III V8

ENGINE

REMOVE

REINSTALL

INSPECTION AND OVERHAUL PROCEDURES

3.12 POWER STEERING PUMP PULLEY

HUB - V6 ENGINE

REPLACE

3.13 POWER STEERING PUMP PULLEY-

GEN III V8 ENGINE – METHOD 1

REPLACE – USING TOOL AU188 & E9239

3.14 POWER STEERING PUMP PULLEY-

GEN III V8 ENGINE – METHOD 2

REPLACE – USING TOOL 7185 & 7005

Techline

3.15 HAND DRIVE POWER RIGHT STEERING

FLUID COOLER AND HOSE/PIPE

ROUTING – V6 ENGINE

ARRANGEMENT

3.16 LEFT-HAND DRIVE POWER STEERING

FLUID COOLER AND HOSE/PIPE

ROUTING – V6 ENGINE

ARRANGEMENT

3.17 RIGHT-HAND DRIVE POWER STEERING

FLUID COOLER AND HOSE/PIPE

ROUTING – GEN III V8 ENGINE

ARRANGEMENT

3.18 LEFT-HAND DRIVE POWER STEERING

FLUID COOLER AND HOSE/PIPE

ROUTING – GEN III V8 ENGINE

ARRANGEMENT

4. DIAGNOSIS

4.1 GENERAL DIAGNOSTIC INFORMATION

4.2 POWER STEERING PUMP

DIAGNOSTIC ITEMS

LEAK DIAGNOSIS

5. SPECIFICATIONS

STEERING GEAR

POWER STEERING PUMP

FRONT WHEEL TOE

LUBRICANTS

SEALANTS

6. TORQUE WRENCH SPECIFICATIONS

STEERING COLUMN ASSEMBLY

POWER STEERING GEAR

V6 POWER STEERING PUMP

GEN III V8 POWER STEERING PUMP

7. SPECIAL TOOLS

1. GENERAL I NFORMATI O N

A power as s isted s teer ing s ystem is f itted as s tandard equipment to all MY 2003 VY and V2 Series Models.

The steering system incorporates;

• A rack and pinion type power steering gear.

• A constant flow vane type power steering pump with remote power steering fluid reservoir for all sedan,

wagon and utility Models.

• A droop flow vane type power steering pump with remote power steering fluid reservoir for all coupe

Models.

• A power steering fluid cooler.

• A four-spoke steering wheel

• An energy absorbing collapsible type steering column incorporating a Tilt/Reach feature, that is

designed to progressively compress under impact from either direction.

The steering Gear used on all right-hand drive vehicles includes a pinion rotary valve housing as a single

piece casting integral with the steering Gear body aluminium casting. The steering Gear used on all left-

hand drive vehicles includes a removable cast iron pinion rotary valve housing that is attached to the

steering Gear body aluminium casting by bolts.

A driver’s airbag is available for all MY 2003 VY and V2 Series Models.

1.1 GENERAL DESCRIPTION - POWER STEERING RACK AND PI NION

The power steering gear features a variable ratio rack and pinion that is made possible by the unique

design of the r ac k teeth. This means that the effec tive pitc h radius of the pinion is les s in the st raight ahead

position than on turns. This results in less turns being required from lock to lock. For example, 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 Gear design.

Referring to Figure 9-1, 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 end and a roller bear ing (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 s pring loaded pad (15), which m aintains slack free adjus tment of the r ack (16)

with the pinion (8).

The tie rods are connec ted to each end of the rack by pre-as sembled soc kets and to the steer ing arms by

sealed for life type tie rod end sockets.

PRINCIPLES OF OPERATION

With the engine running and the steering wheel in

the neutral position (s traight ahead) , power steering

fluid flows continuously from the power steering

pump to the steering gear and back to the pump,

via the power steering fluid reservoir. In this

steering mode, very little pressure is required to

maintain the high power s teering fluid flow rate that

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

is required to operate the system.

When turning the steering wheel to either side,

power steering fluid 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

power steering 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.

Power steering fluid is fed to the valve (➨) and from

there, to the left ( 4) and right (5) sides of the power

piston via circumferential grooves in the outer

sleeve, that are sealed by PTFE seals (6). Excess

power steering fluid is returned to the reservoir.

The outer s leeve is coupled by a s tepped 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 power steering fluid and providing power

assistance as needed.

Figure 9-1

POWER STEERING GEAR

Figure 9-2

Legend

A. Rack Grain B. Rack Travel 1. Clamp Bolt Flat

POWER STEERING FLUID FLOW

NEUTRAL POSITION (STRAIGHT AHEAD)

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

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

this attitude, power steering fluid flow from the

pump (4) is directed 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 power steer ing fluid to pass equally

to both sides of the rack (3) piston (shown as

'Static' because no power steering fluid actually

flows to and fr om the st eering gear). T he bypass ed

power steering fluid returns to the power steering

fluid reservoir (5) through holes drilled in the

longitudinal grooves of the inner valve. With an

equal pressure applied to both sides of the rack

piston, no power assistance is provided.

Figure 9-3

TURNING RIGHT

When turning to the right, as soon as relative

motion between the inner rotating valve (1) and

outer sleeve (2) occurs, power steering fluid is

restricted in its free return to the pump and is

routed to the right-hand side of the rack piston. At

the sam e time, power s teering fluid on the opposite

side of the piston is directed to the return circuit,

leading to the reservoir (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 9-4

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

restriction, power steering fluid is routed to the left-

hand side of the rack piston (3), providing the

required assistance. Also, power steering 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 amount of assistance

provided by the power steering fluid, is determined

by the restriction 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 9-5

INNER VALVE MEMBER

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

by the power steering fluid. In order to achieve a

balance between this graduated increase of

assistance and maintain a realistic 'feel' with good

response as the r oad speed inc r eases , the gr ooves

(2) of the inner rotating valve (1) are precisely

shaped to meter the flow of POWER STEERING

FLUID.

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 9-6

1.2 GENERAL DESCRIPTION - POWER STEERING PUMP

Hydr aulic pres sure f or the power steer ing system is

provided by a SAGINAW 'N' Series, vane type

pump.

For vehicles fitted with a V6 engine, the power

steering pump (1) is mounted on a retaining

bracket, attached to the right-hand side of the

cylinder block. The remote power steering fluid

reservoir is mounted on a bracket attached to the

radiator.

Figure 9-7

For vehicles fitted with a Gen III V8 engine, the

pump (1) is attached by two bolts (2) to the left-

hand side cylinder head. The remote power

steering fluid reservoir is mounted on a bracket

attached to the engine directly above the power

steering pump.

Figure 9-8

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 9-9

THRUST PLATE

The thrust plate is located on the inner face of the

housing by two dowel pins. This plate has six

cavities; the four central cavities (1) supply under-

vane power steering fluid pressure, and the two

outer cavities ( 2) direct dischar ge pressure through

the cross-over holes in the pump ring, through to

the pres sur e plate and then on to the s teering gear .

The outside slots (3) are for power steering fluid

intake from the suction part of the pump to the

rotor.

Figure 9-10

PUMP RING

The end f aces of the pum p ring are ground flat and

parallel. The centre hole is a two lobed cam in

which the rotor and vanes operate, providing two

cycles per revolution. The r ing is placed next to the

thrust plate and located with the same two dowel

pins used to locate the thrust plate on the inner

face of the housing.

Figure 9-11

PRESSURE PLATE

The pressure plate is fitted against the pump ring

and located with the same two dowel pins used to

locate the thrust plate and pump ring. This plate

has two central ports (1) for under-vane power

steering fluid pressure. The two outer ports (2)

pass power steer ing fluid under discharge pressur e

through the control valve, to the steering gear.

The two outer slots (3) in the press ure plate are for

intake of the power steering fluid from the suction

side of the pump.

Figure 9-12

DRIVE SHAFT AND ROTOR

The drive s haf t is f itted with a belt driven pulley from the engine c rankshaf t. T he pum p rotor is splined to the

drive shaft and is located within the pump ring between the thrust and pressure plates. Ten vanes are

mounted in radial slots around the rotor. The shaft is supported by a bush, pressed into the front of the

pump housing.

DROOP FLOW CONTROL VALVE ASSEMBLY

The purpose of the control valve assembly fitted to

droop f low des ign pumps, is to var y power steering

system pressure and power steering fluid flow to

the steering gear as required, under various

operating conditions.

The control valve assembly consists of the control

valve plunger (1), an internal pressure relief ball

check (2), ball check guide and ball check guide

spring ( 3). A sc reen (4) in the end of the plunger , is

designed to keep dirt and foreign material out of the

ball check area.

Movement of the control valve assembly under

power steering fluid pressure and spring (5) force,

acts upon a power steer ing fluid control needle and

spring (6), in the pump outlet fitting (7) . T he needle

is tapered and movement within the outlet fitting

orifice hole, changes the am ount of power steering

fluid flow to the steering gear.

Figure 9-13

FILLING THE PUMP

When the pump and power steering gear are completely empty of power steering fluid, adding power

steering fluid to the reservoir will fill the pump housing assembly.

Suction and gravity draw power steering fluid into the intak e section of the pump, caus ing it to flow through

a drilled passage in the housing, leading to the large cavity around the rotor ring. The power steering fluid

fills this area and also the two intake openings on the pressure and thrus t plates, filling the space between

the ring and rotor as sembly. Any air that m ight enter the system is automatically rem oved by the circulating

power steering f luid, from the pum p, thr ough the power steering f luid circuit to the s teering gear and then to

the reservoir, where it vents to atmosphere, via the reservoir cap.

CONSTANT FLOW CONTROL VALVE OPERATION

SLOW CORNERING (FIGURE 9-14)

Pump s peeds during s low cornering or park ing are norm ally low, as are demands for fluid flow volume, due

to slower steering manoeuvres.

With reasonably high relative movement of the inner valve and outer sleeve in the steering Gear control

valve at this tim e, the fluid is pressuris ed to approxim ately 3,400 k Pa to 4,800 kPa and direc ted to the high

pressure cavity behind the pressure plate. Discharge ports direct this fluid to the outlet fitting (1) and then

on to the steering gear.

The discharge fluid pressure from the outlet fitting, is slightly lower in pressure than the internal high

pressure (A), coming from the pump ring.

This drop in pressure, due to venturi action, occurs as the fluid flows through the orifice (2) in the outlet

fitting.

This lower pressure is transmitted to the spring (3) end of the control valve (4) by a fluid passage (5)

connecting the control valve to the outlet fitting.

This results in a pressure unbalance at each end of the control valve, causing it to move away from the

outlet fitting. Owing to the force of the control valve spring, the valve remains closed to the fluid by-pass

hole.

Because sufficient fluid is allowed to circulate through the system, fluid pressure does not build up high

enough to cause the pressure relief ball check in the valve.

Figure 9-14

MODERATE TO HIGH SPEED OPERATION (FIGURE 9-15)

System pressure in this mode is normally low (approximately 260 kPa) due to the lack of steering

manoeuvres and high fluid flow rates. When the steering is in the straight ahead position, fluid is discharged

from the high pressure cavity (A), through the outlet fitting (1) to the steering gear and back to the pump

reservoir.

When this flow exceeds a preset level, fluid is by-passed within the pump, as follows:

Fluid passing through the outlet fitting, causes a pressure reduction to occur in the orifice (2) by venturi

action.

This reduced pressure is transmitted to the spring (3) end of the control valve (4), via the fluid by-pass

passage (5) connecting the control valve and the outlet fitting, as shown.

This pressure dif ference on each side of the control valve, causes the valve to move against spring force,

opening the fluid by-pass passage (A) to the pump inlet. Depending on vehicle road speed, pump speed

and the steering requirements needed by the driver, this valve will modulate, controlling the fluid flow rate

through the steering system.

Figure 9-15

CORNERING AGAINST WHEEL STOPS (FIGURE 9-16)

When the steering wheel is turned to full lock and held in that position, the steering rack power piston

chamber becomes fully pressurised and fluid flow stops.

NOTE: Th is full lock condition should not be m aintained f or long periods of time ( in excess of five minutes)

due to excessive fluid temperature rise.

The resulting high pressure is then transmitted to the spring (1) end of the control valve (2) through the

connecting fluid passage (3) from the outlet fitting.

When the pressur e builds up high enough, the relief ball chec k ( 4) within the control valve opens , allowing a

small amount of fluid to pass through the pressure relief orifice, causing a pressure drop that results in a

lower pressure acting on the spring end of the control valve. The control valve then moves against spring

forc e and opens up the f luid by-pas s pas sage (A) s o that fluid is returned to the pump inlet. Pre-determ ined

relief pressure is thus maintained while the steering gear is turned and held on full lock.

Figure 9-16

DROOP FLOW CONTROL VALVE OPERATION

The mode of operation of the power steering pump is based upon the demand of the power steering gear.

The various major modes of operation are:

1. Slow cornering.

2. Moderate to high speed straight ahead driving.

3. Cornering against the wheel stop.

The pump is designed to recognise these conditions and compensate for them internally.

As the pump drive s haf t tur ns the rotor , the vane tips f ollow the inner c am sur f ace of the pum p r ing, moving

outward and inward twice during each revolution. This results in a complete pumping cycle every 180° of

rotation. Power steering fluid is moved in the spaces between the vanes. As the vane tips move outward,

power steering fluid enters the inter-vane spaces through four suction ports in the pressure and thrust

plates. As the vane tips move inwards, the pressure of the power steering fluid is raised and the power

steering fluid is discharged from the pump ring. High pressure fluid discharges into a cavity, behind the

pressure plate. A portion of this power steering fluid is circulated through the central port system in the

pressure plate, forcing the vanes to follow the cam surface of the ring.

Power steering fluid is discharged from the high pressure cavity, through the outlet fitting to the steering

gear. As the power steering fluid passes through the outlet fitting, the power steering fluid pressure drops.

This reduced pressure is transmitted to the spring end of the control valve.

SLOW CORNERING (FIGURE 9-17)

Pump speeds during slow cornering or parking are normally low, as are demands for power steering fluid

flow due to slower steering manoeuvres.

The power steering fluid is pressurised to approximately 3,400 kPa to 4,800 kPa and directed to the high

pressur e cavity behind the pres sure plate (arrow ‘A’). Disc harge ports direct this power steer ing f luid to the

outlet fitting (4) and then to the steering gear.

The discharge power steering fluid pressure from the outlet fitting (4), is slightly lower in pressure than the

internal high pressure coming f rom the pump ring. T his drop in pr essure occ urs as the power steer ing fluid

flow passes the needle (3) and orifice in the outlet fitting.

Figure 9-17

This lower pressure is transmitted to the spring (2) end of the control valve (1) by a power steering fluid

passage (5), connecting the control valve to the outlet fitting (4).

This results in a pressure unbalance on the valve itself.

The control valve ( 1) m oves away from the outlet fitting (4), but due to the f orce of the contr ol valve spring

(2), the valve remains closed to the power steering fluid by-pass hole (B). The movement of the control

valve (1), contr ols the needle valve (3) in the outlet fitting (4 ) and this controls the power st eering fluid flow

to the steering gear.

Because power steer ing f luid pres s ure is not high enough to c aus e the pres s ure r elief ball check to actuate,

the external circuit through the steering gear, allows power steering fluid to recirculate through the entire

system.

MODERATE TO HIGH SPEED OPERATION (FIGURE 9-18)

System pressures in this mode are normally low (approximately 260 kPa) due to the lack of steering

manoeuvres.

Power steering f luid is discharged fr om the high press ure cavity through the outlet fitting (4) to the steering

gear. As power steer ing fluid pass es through the f itting, a pres sure drop oc curs acros s the needle valve (3)

and orific e. This reduced pr essur e is trans m itted to the spring ( 2) end of the control valve (1), via the power

steering fluid passage (5).

This pressure differential, causes the control valve (1) to move and open up the power steering fluid by-

pass passage (B) to the pum p inlet. The movem ent of the control valve (1) also controls the movement of

the flow control needle (3) in the outlet fitting (4). The needle closes in the orifice and power steering fluid

flow to the steering gear is reduced.

Figure 9-18

CORNERING AGAINST WHEEL STOPS (FIGURE 9-19)

When the steering wheel is turned to full lock and held in that position, the steering Gear power piston chamber

becom es f ully pressuris ed and power steer ing f luid f low stops. The res ulting high pres s ure is then trans mitted to the

spring (5) end of the control valve (1) by connecting power steering fluid passage (8) from the outlet fitting.

When the pressure relief ball check (2) within the control valve opens, a small amount of power steering fluid

passes through the pressure relief orifice, creating a pressure drop, acting on the spring end of the control valve.

The control valve then m oves back against spring for ce (5), opening the power steering f luid by-pass passage (B).

Power steering fluid then returns to the pump inlet. Pre-determined relief pressure is thus maintained while the

steering gear is turned and held on full lock.

NOTE: This condition should not be maintained for long periods of time due to excessive power steering fluid

temperature rise.

Figure 9-19

1.3 GENERAL DESCRIPTION - STEERING COLUMN

The steering colum ns fitted to MY 2003 VY and V2 Series Models include a combination ignition/steering lock, are

of an energy absorbing design and will progressively compress under impact from either direction.

In addition, all steering columns are equipped with a Tilt/Reach feature, as an integral part of their design.

The ignition/steering lock is located to the right of the column assembly. The body of the lock assembly forms an

integral part of the column outer tube and cannot be removed/replaced as a separate component.

The s teering lock is activated when the 'lock ' position is s elected and the lock mechanism is released and engages

into a slot in the steering shaft (when the slot is facing the lock mechanism).

The ignition switch is attached to the left-hand end of the ignition/steering lock housing.

The end of the ignition bar rel ass embly shaf t is stepped and engages with the ignition switch. T he ignition switch is

activated as the lock cylinder is rotated.

Connecting the steering shaft to the steering gear, is an integral steering coupling, which features two universal

joints and a vibration damper.

The following features determine the steering column assembly collapse behaviour in the event of a collision.

A. Upper End of the Steering Column

The upper end of the steering column is fastened to the instrument panel by a bracket with two inserts at the

mounting point, and held in pos ition by two bolts. Under collis ion conditions, should the vehicle operator not be

wearing a seat belt, and sufficient force be exerted by the person against the steering wheel and the deployed

air bag, the bracket is able to move away from the inserts, the amount being controlled by a coiled spring on

each side. This enables the upper end of the steering colum n to move down, within a specified load range, in

this extreme situation.

Collapse load control is achieved primarily by the breaking away of the mounting bracket from the two inserts

and the tension applied by the two control springs.

B. Telescoping Shaft Assembly

The shaft ass embly consists of an upper tube that slides over a lower shaf t, thus allowing the s haft to transm it

torque but still collapse during impact.

C. Steering Wheel Inflatable Restraint (Driver’s Airbag)

This component is designed to supplement the lap/sash seat belt, driver restraint system also fitted to the

vehicle. Under no circumstances is the driver’s airbag expected to replace the need for the driver to

wear a seat belt.

CAUTION: Before any servicing operations are considered, that could in any way impinge on the operation

of the Occupant Protection System (OPS) and/or the personal safety of the individual working on the

vehicle, the cautionary notes detailed under 2.1 STEERING COLUMN ASSEMBLY SERVICE NOTES AND

PRECAUTIONS, must be read and complied with!

Figure 9-20

Legend

1. Steering Column Bracket Assembly

2. Steering Column Upper Trim Cover

3. Steering Column Lower Trim cover

4. Lower Trim Cover To Column Attaching Screw

(1 place)

Steering Column To Upper Mount Attaching Bolt

(2 places)

5. Steering Column To Steering Gear Coupling

7. Steering Gear Assembly

8. Steering Column Coupling Cam Bolt (1 place)

9. Steering Column Coupling Crimp Nut (1 place)

10. Dash Lower Panel

11. Steering Shaft Lower Bearing Support Attaching

Nuts (2 places)

2. STEERING COLUMN ASSEMBLY SERVICE OPERATIONS

2.1 STEERING COLUMN ASSEMBLY SERVICE NOTES AND PRECAUTIONS

CAUTION: Disable the OPS (Air Bag). Refer to Section 12M, 2.2 SYSTEM ENABLING AND DISABLING

PROCEDURE.

CAUTIONARY NOTES:

1. The outer jacket, steering shaft and instrument panel mounting bracket are designed as energy absorbing units.

Because of the des ign of thes e components, it is absolutely vital that the steer ing column ass embly is handled

with care when performing any of the required service operations. Avoid hammering, jarring, 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.

2.2 OCCUPANT PROTECTION SYSTEM DISABLING AND ENABLING PROCEDURE

IMPORTANT: While sim ply disconnecting the battery earth lead from the batter y terminal is suf f icient to disable the

air bag/s fitted to MY 2003 VY and V2 Series vehicles, this would also m ean losing radio PIN setting (if the battery

were to rem ain disconnec ted for m ore than approx im ately 8 hours) and BCM progr am m ing. The procedure detailed

in 2.2 SYSTEM ENABLING AND DISABLING PROCEDURE in Section 12M, OCCUPANT PROTECTION

SYSTEM, describes an approach that disables the driver’s air bag, rendering it safe to work on steering

com ponents but allowing all pre-sets to rem ain intact. F or detailed inform ation regarding enabling and dis abling the

Occupant Protection System, refer to Section 12M, 2.2 SYSTEM ENABLING AND DISABLING.

2.3 HORN BAR & DRIVER’S AIRBAG ASSEMBLY

LT Section No. – 06-225

All MY 2003 VY and V2 Series Models are fitted with an Occupant Protection System (OPS) that incorporates a

driver’s airbag m ounted into the pad on the front of the steering wheel. The driver’s airbag assem bly also includes

the horn bar . For all the r elevent s ervic e inf ormation r egarding the hor n bar and driver ’s air bag as s embly as fitted to

MY 2003 VY and V2 Series Models, refer to Section 12M, 2.3 HORN BAR AND DRIVER’S AIRBAG ASSEMBLY.

Techline

2.4 STEERING WHEEL ASSEMBLY

LT Section No. – 06-225

REMOVE

CAUTION: Disable the OPS (Air Bag). Refer to Section 12M, 2.2 SYSTEM ENABLING AND DISABLING

PROCEDURE.

1. Remove the steering column upper and lower trim covers, refer to Section 1A3, 3.21 INSTRUMENT PANEL

PAD ASSEMBLY.

2. Rem ove the steering wheel inflatable restraint module, refer to Section 12M, 2.3 HORN BAR AND DRIVER’S

AIRBAG ASSEMBLY.

NOTE: A Special Tool is required to remove the driver’s airbag module.

3. Place the road wheels in the straight-ahead position and lock the steering column.

4. Using a suitable socket, remove the screw (1).

5. Remove the steering wheel assembly,

disconnecting and feeding the wires through the

aperture in the wheel assembly as required.

NOTE: A puller should not be required, however, if the

wheel assembly cannot be removed fairly easily, use

puller J1859-A and legs E1408.

6. Check that the green indicator (2) on the coil

assembly - inflatable restraint steering wheel

module has engaged the inner cloc k spr ing to lock

it in the central position.

Figure 9-21

REINSTALL

1. Ensure the road wheels are in the straight-ahead position and the green indictor on the coil assembly - inflatable

restraint steering wheel module is visible.

2. Install the wheel assembly in its correct orientation, feeding the wires through the aperture.

3. Clean the threads of the steering wheel screw and steering shaft and apply Loctite 242 or equivalent to the

screw.

4. Tighten the screw to the specified torque.

5. Connect the wiring connectors as required.

6. Install the driver’s airbag assembly, refer to Section 12M, 2.3 HORN BAR AND DRIVER’S AIRBAG.

7. Install the covers - steering column upper and lower trim, refer to Section 1A3, 3.21 INSTRUMENT PANEL

PAD ASSEMBLY.

STEERING WHEEL

ATTACHING SCREW

TORQUE SPECIFICATION 40 – 50 Nm

8. Enable the OPS (Air Bag). Refer to Section 12M, 2.2 SYSTEM ENA BLING AND DISABLING PROCEDURE.

9. Check horn and turn indicator operation.

Techline

2.5 IGNITION BARREL LOCK CYLINDER

LT Section No. – 06-255

REMOVE

CAUTION: Disable the OPS (Air Bag). Refer to Section 12M, 2.2 SYSTEM ENABLING AND DISABLING

PROCEDURE.

1. Disconnect battery earth lead.

2. Remove the ignition keys from the ignition

switch.

3. Lower the instrument panel lower fuse panel

cover assembly (1) by grasping the top edge on

each side of the steering c olum n with the f inger

tips and pulling the top edge out, to free the

retaining lugs (2) from the clips (3).

4. Release the steering column tilt/reach clamp

lever, lower the column and lock the clamp

lever in this position.

5. Remove the steering column upper and lower

trim covers, refer to Section 1A3, 3.21

INSTRUMENT PANEL PAD ASSEMBLY.

Figure 9-22

6. Disconnect the wiring harness connector (1)

and ignition lock illumination socket (2) and

bulb (3) from the key reader assembly (4).

7. Carefully pull the key reader from the ignition

lock assembly housing.

Figure 9-23

8. Insert ignition key into barrel and turn to the

'ON' position.

9. Insert a 2.5 mm diameter pin (an Allen key is

suitable) (1), into locking pin hole, depress

spring loaded barrel locking latch to release

lock cylinder.

10. Remove pin and pull barrel (2) from lock

housing.

Figure 9-24

REINSTALL

1. Install the key into the ignition barrel and turn the ignition to the 'ON' position.

2. Insert the barrel into the lock housing until the latch locks into the housing.

3. Install the ignition k ey reader (2), align the flats

(A) and indexing lug (B) of the remote key

reader assembly (2), with the mating groove

Figure 9-25

4. Gently press the key reader assembly (1) onto

the ignition lock (2) by pushing evenly between

the two key reader seats, until the reader

assembly seats onto the ignition lock.

5. Ensure that the wiring harness connector and

ignition lock illumination bulb and socket are

securely fitted to the key reader assembly.

6. Install the steering column lower cover, by

engaging the two retaining tangs before

pushing the cover towards the instrument

cluster to engage. W hen the holes are aligned,

install the lower cover attaching screw.

7. Install the upper c over in the r evers e manner to

removal.

8. Raise the instrument panel right-hand cover

assem bly and locate each tang in its respective

clip before firmly pushing home to secure.

9. Reconnect the battery earth lead.

10. Insert the ignition k ey and chec k ignition switch

lock and barrel operations.

IMPORTANT: Enable the OPS (Air Bag). Refer to

Section 12M, 2.2 SYSTEM ENABLING AND

DISABLING PROCEDURE.

Figure 9-26

2.6 IGNITION SWITCH

LT Section No. – 06-255

REMOVE

CAUTION: Disable the OPS (Air Bag). Refer to Section 12M, 2.2 SYSTEM ENABLING AND DISABLING

PROCEDURE.

1. Disconnect the battery earth lead.

2. Remove the ignition keys from the ignition

switch.

3. Lower the instrument panel lower fuse panel

cover assembly (1) by grasping the top edge on

each side of the steering c olum n with the f inger

tips and pulling the top edge out, to free the

retaining lugs (2) from the clips (3).

4. Release the steering column tilt/reach clamp

lever, lower the column and lock the clamp

lever in this position.

5. Remove the steering column upper and lower

trim covers, refer to Section 12M, 3.21

INSTRUMENT PANEL PAD ASSEMBLY.

Figure 9-27

6. Disconnect the wiring harness connector (1)

and ignition lock illumination socket (2) and

bulb (3) from the key reader assembly (4).

7. Carefully pull the key reader from the ignition

lock assembly housing.

Figure 9-28

8. Insert the ignition key into the barrel and turn to

the 'ON' position.

9. Insert a 2.5 mm diameter pin (an Allen key is

suitable) (1), into the locking pin hole, depress

the spring loaded barr el lock ing latch to release

the lock cylinder.

10. Rem ove the pin and pull the barrel (2) from the

lock housing.

Figure 9-29

11. Disconnect the wiring harness connector from

the ignition switch.

12. Using a fine bladed screwdriver, remove the

ignition switch to steering lock housing

retaining grub screw (arrow).

13. Pull the switch from the steering lock housing,

disengaging the roll pin from the side opposite

the grub screw.

Figure 9-30

TESTING SWITCH

CAUTION: Disable the OPS (Air Bag). Refer to Section 12M, 2.2 SYSTEM ENABLING AND DISABLING

PROCEDURE.

1. Disconnect the battery earth lead.

2. Lower the instrument panel lower fuse panel

cover assembly (1) by grasping the top edge on

each side of the steering c olum n with the f inger

tips and pulling the top edge out, to free the

retaining lugs (2) from the clips (3).

3. Release the steering column tilt/reach clamp

lever, lower the column and lock the clamp

lever in this position.

4. Remove the steering column upper and lower

trim covers, refer to Section 1A3, 3.21

INSTRUMENT PANEL PAD ASSEMBLY.

Figure 9-31

5. Disconnect the wiring harness connector (1)

from the ignition switch (2).

Switch

Terminals Switch

Position Indication if

Okay

30 and 15a Continuity

30 and 15 Open

30 and 50 Open

15a and 15 Open

15a and 50 Open

15 and 50

ACC

Open

30 and 15a Continuity

30 and 15 Continuity

30 and 50 Open

15a and 15 Continuity

15a and 50 Open

15 and 50

IGN

Open

30 and 15a Open

30 and 15 Continuity

30 and 50 Continuity

15a and 15 Open

15a and 50 Open

15 and 50

START

Continuity

Figure 9-32

REINSTALL

Installation of the ignition switch is the reverse of the removal procedure, noting the following points:

1. When ins talling the ignition switch into the housing, ensure that the s witc h body engages the locating roll pin in

the housing and that the slot in the end of the switch aligns with the stepped end of the ignition barrel shaft.

2. Once fitted, retain the switch by tightening the grub screw.

3. After installing the wiring harness connector to the ignition switch, reconnect the battery earth lead and check

the ignition switch operation.

IMPORTANT: Enable the OPS (Air Bag). Refer to Section 12M, 2.2 SYSTEM ENABLING AND DISABLING

PROCEDURE.

2.7 STEERING LOCK

As the steering lock is an integral part of the steering column assembly, it is not a separately serviceable

component. Should the steering lock be found to be faulty, the entire steering column assembly must be replaced.

For steering column replacement procedures, refer to 2.9 STEERING COLUMN ASSEMBLY in this Section.

2.8 STEERING COLUMN UPPER BEARING

As the steering column upper bearing is an integral part of the steering column assembly, it is not a separately

serviceable c omponent. Should the s teering colum n upper bearing be found to be faulty, the entire steering colum n

assembly must be replaced. For steering column replacement procedures, refer to 2.9 STEERING COLUMN

ASSEMBLY in this Section.

2.9 STEERING COLUMN ASSEMBLY

LT Section No. – 06-253

REMOVE

CAUTION: Disable the OPS (Air Bag). Refer to Section 12M, 2.2 SYSTEM ENABLING AND DISABLING

PROCEDURE.

1. Disconnect the battery earth lead.

2. Remove the instrument panel lower trim panel assembly, refer to Section 1A3, 3.3 INSTRUMENT PANEL

LOWER TRIM PANEL ASSEMBLY.

3. Remove the steering column upper and lower trim covers, refer to Section 1A3, 3.21 INSTRUMENT PANEL

PAD ASSEMBLY.

4. Remove the steering wheel inflatable restraint module, refer to Section 12M, 2.3 STEERING WHEEL

INFLATABLE RESTRAINT in 12M, OCCUPANT PROTECTION SYSTEM.

5. Remove the steering wheel, refer to 2.4 STEERING WHEEL ASSEMBLY in this Section.

6. Remove the clock spring coil, refer to Section 12M, 2.6 CLOCK SPRING COIL.

7. Remove the instrument panel lower trim retainer, refer to Section 1A3, 3.4 INSTRUMENT PANEL LOWER

TRIM PLATE RETAINER.

8. Remove the lower instrument lower trim plate assembly, refer to Section 1A3, 3.1 INSTRUMENT PANEL

LOWER TRIM PLATE ASSEMBLY.

NOTE: For steering column removal, it is not necessary to completely remove the instrument panel lower trim

panel. For this procedur e, leave the Data Link Connector (DLC) attached to the panel, swing the panel to one side

and secure with tie wire or similar.

9. Remove the driver’s side instrument panel outer cover, refer to Section 1A3, 3.19 INSTRUMENT PANEL

OUTER COVER.

10. Remove the driver’s side HVAC unit to driver’s door inner duct, for all MY 2003 VY and V2 Series Models,

regardless of the type of heating and air-conditioning system, refer to Section 2B, 3. HVAC OCCUPANT

CLIMATE CONTROL (MANUAL A/C).

11. Remove the ignition barrel lock cylinder, refer to 2.5 IGNITION BARREL LOCK CYLINDER in this Section.

12. Remove both the turn signal and wiper/washer switch assemblies, refer to Section 1A3, 3.21 INSTRUMENT

PANEL PAD ASSEMBLY, steps 14 and 15.

13. Loosen but do not remove the steering column to instrument panel mounting bolts.

14. Raise the front of the vehic le and plac e on safety s tands. Refer to Section 0A, GENERAL INFORMATION for

location of jacking points.

15. Remove steering coupling to steering Gear

pinion shaft cam bolt nut (1). Remove the cam

bolt (2), then disengage the retaining clip (3)

and slide the coupling (4) away from the

steering Gear pinion shaft.

Figure 9-33

16. From inside the vehicle, remove the two nuts

(1) securing the lower housing assembly (2) to

the floorpan.

17. While supporting the steering column, remove

the previously loosened upper colum n retaining

bolts.

18. Remove the steering column assembly from

the vehicle.

Figure 9-34

REINSTALL

The installation procedure for the steering column assembly is the reverse of the removal procedures, noting the

following points:

1. Inspect the foam seal s tuc k to the lower housing to ensur e it is intac t. If the s ealing ability of the f lattened seal is

suspect, apply a continuous bead of silicone sealant such as RTV 732 or equivalent to the seal material.

2. After installing the steering column coupling through the floor pan, install the two lower housing retaining nuts

but do not tighten at this stage.

3. Lift the column assembly and loosely install the two upper support bracket retaining bolts.

NOTE: Only use bolts that were originally used, or

replace with genuine parts, as these parts are an

inherent part of this vital safety feature of the

vehicle.

4. Engage the lower coupling with the steering

rack input shaft, install the cam bolt and a new

'crim p' nut to the lower coupling and tighten the

nut to the specified torque.

LOWER STEERING COUPLING

TO RACK PINION, CAM BOLT

NUT TORQUE SPECIFICATION 25 – 30 Nm

Figure 9-35

1. Tighten the lower housing retaining nuts from inside the vehicle, to the specified torque.

STEERING COLUMN LOWER

HOUSING RETAINING NUTS

TORQUE SPECIFICATION 15 – 30 Nm

2. Tighten the two upper bracket to instrument panel mounting nuts to the correct torque specification.

UPPER STEERING COLUMN

MOUNT ATTACHING NUTS

TORQUE SPECIFICATION 15 – 30 Nm

3. The rem ainder of the ins tallation proces s is the reverse of the removal steps , with the exception of the following

important points:

4. Install the clock spring assembly as follows:

a. To avoid irreparable damage to the clock spring coil ribbon wire, ensure that the steering gear is in the

centralised pos ition. Refer to either 3.6 RIGHT -HAND DRIVE POWER STEERING GEAR and 3.7 LEFT-HAND

DRIVE POWER STEERING GEAR in this Section for the required details.

b. With the clock spring assembly locked in the centralised position, install the assembly over the steering shaft,

indexing the lower locating pins on the clock spring, with matching holes in the switch housing.

c. Push the clock spring assembly onto the switch housing until the four locking tangs fully engage.

NOTE: If the clock spring assembly was removed without being centred, refer to CENTRING THE CLOCK COIL

below.

5. Install steering wheel, refer to 2.4 STEERING WHEEL ASSEMBLY in this Section.

6. Connect the battery earth lead and check the operation of all affected electrical items.

CENTRING THE CLOCK SPRING COIL

All MY 2003 VY and V2 Series Models are fitted with an Occupant Protection System (OPS) that incorporates a

clock spring c oil as s embly behind the dr iver ’s air bag and hor n bar as s embly. For all the relevent ser vice inf or mation

(including the remove, reinstall and centring procedures) regarding the clock spring coil assembly as fitted to MY

2003 VY and V2 Series Models, refer to Section 12M, 2.6 CLOCK SPRING COIL.

2.10 CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE

IMPORTANT:

When MY 2003 VY and V2 Series vehicles are involved in an accident resulting in major body or sheet metal

damage or where the steering column has been impacted, column damage or misalignment may also have

occurred.

INSPECT:

1. Check visually to s ee that either or both of the two mounting lugs have been dis lodged f rom the column br acket

and that the control springs are undamaged.

2. Visually check for any damage to the column and/or shaft that causes binding or jamming.

Should any component of the steering column assembly show signs that distortion has occurred, then the column

must be replaced as an assembly.

For steering column assembly replacement procedures, refer to 2.9 STEERING COLUMN ASSEMBLY in this

Section.

2.11 TILT/RE ACH HANDLE

LT Section No. – 06-253

REPLACE

NOTE: While replacem ent of this com ponent is not

recommended, the handle is serviced separately.

1. Release the tilt/reach handle (1) and, while

supporting it with one hand, remove the

through bolt, nut cover (7) and retaining nut (6).

2. W ithdraw the through bolt and handle (1), inner

cam (2), outer rac k (3) , washer (4) and bearing

(5).

3. Install through bolt and replacem ent handle (1),

through the inner cam (2).

4. Apply Loctite 242 (or equivalent) to the bolt

thread.

5. Install the rem aining c omponents in the reverse

order to removal and install a NEW retaining

nut (6).

IMPORTANT: T he final tension on the through bolt

determines the security of the upper steering

colum n assem bly and the f inal nut tens ion must be

determined by adopting the following procedure.

6. T ighten the nut until a f orce of 80 N is requir ed

to push the lever closed.

7. W ith the lever released, check that the column

is free to slide up and down. If the Gear (3)

grates, loosen the nut just sufficient to allow

free movement of the column.

8. Install the nut cover (7).

Figure 9-36

2.12 STEERING COLUMN LOWER BEARING ASSEMBLY

As the lower bearing is an integral part of the steering column assembly, it is not a separately serviceable

com ponent. Should the lower bearing be found to be f aulty, the entire s teering colum n assem bly must be replaced.

For steering column replacement procedures, refer to 2.9 STEERING COLUMN ASSEMBLY in this Section.

2.13 STEERING COUPLING

As the steering coupling is an integral part of the steering column assembly, it is not a separately serviceable

component. Should the steering coupling be found to be faulty, the entire steering column assembly must be

replaced. For steering column replacement procedures, refer to 2.9 STEERING COLUMN ASSEMBLY in this

Section.

3. POWER STEERING SERVICE OPERATIONS

IMPORTANT

All steering fasteners are important attaching parts as they affect the performance of vital components

and/or cou ld resu lt in major rep air expen se. Wh ere specif ied in this section, fasteners M UST be replaced

with parts of the same part number or a GM approved equivalent. Do not use fasteners of an inferior

quality or substitute design.

Torque values must be used as specified during reassembly to ensure proper retention of all steering

components.

Through-out this section, fastener torque w rench specifications may be accompanied with the following

identification marks:

+ Fasteners must be replaced after loosening.

& Vehicle must be at kerb height before final tightening.

6 Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock

and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

3.1 POWER STEERING FLUID LEVEL CHECK

V6 ENGINE

The power steering fluid level can be checked by

viewing the level through the translucent plastic

side of the reservoir.

If the power steering fluid is cold, the level should

be in the ‘COLD’ range. Similarly, if it is hot, the

power steering f luid should be in the ‘HO T ’ r ange. If

the power steering fluid level is at the low side of

either range, new power steering fluid should be

added to bring the level into the correct range and

the system checked for the cause of the leakage

and corrected as necessary.

NOTE: The recommended power steering fluid for

use in all MY 2003 VY and V2 Series vehicles, is

Dexron® III automatic transmission fluid to Holden’s

Specification HN2126.

Figure 9-37

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 power steering fluid is cold, the level should

be in the ‘COLD’ range. Similarly, if it is hot, the

power steering f luid should be in the ‘HO T ’ r ange. If

the power steering fluid level is at the low side of

either range, new power steering fluid should be

added to bring the level to the corr ect point and the

system checked for the cause of the leakage and

corrected as necessary.

NOTE: The recommended power steering fluid for

use in all MY 2003 VY and V2 Series vehicles, is

Dexron® III automatic transmission fluid to Holden’s

Specification HN2126.

Figure 9-38

3.2 DRIVE BELT ADJUSTMENT

LT Section No. – 01-003

V6 ENGINE

For vehicles with V6 engine, the power steering pump is driven by the engine serpentine dr ive belt. The belt is self

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

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.

Techline

3.3 HYDRAULIC SYSTE M, BLEE DING/RE FILLING PROCEDURE

LT Section No. – 06-400

CAUTIONARY NOTES:

1. If the power steering fluid level is low in the power steering fluid reservoir, air will be drawn in and mixed with the

power steer ing fluid in small bubbles. If the pump is allowed to continue oper ation, an increasing am ount of air

will be drawn into the s ystem , c ausing the power s teer ing f luid volume to increas e to a point where the r eser voir

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 power steering 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 Gear assembly requires replacem ent, a large volume of air will be required to be purged, which

means that the power steering 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 the front of the vehicle and place on safety stands. Refer to Section 0A, GENERAL INFORMATION.

2. W ith the engine not running, add the power steering fluid to reservoir to the maximum mark (or greater, if it is

known that the steering gear is empty).

3. Start the 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 power steering 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 power steering 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 from four

to six times. Stop the engine and top up the power steering 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 power steering fluid for a prolonged period.

This is usually achieved automatically after two to three days, 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 diff ic ulties . This 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 performing the hydraulic circuit test, carefully check the power steering fluid level, drive belt condition 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 the press ure gauge assem bly (Hose set AU392 and G auge assem bly E1461-1) between the outlet fitting

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

4. Refill the system with power steering fluid to the correct level, refer to 3.1 POWER STEERING FLUID LEVEL

CHECK in this Section. Ensure that there are no leaks at either the hose or gauge connections.

5. Bleed the air from the system, as described in 3.3 HYDRAULIC SYSTEM, BLEEDING / REFILLING

PROCEDURE in this Section.

Figure 9-39

TEST 1 - HYDRA ULIC CIRCUIT OPEN

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

connections for leakage.

2. Insert the thermometer into the reservoir filler opening and move the steering from lock to lock until power

steering fluid reaches 75° Celsius.

3. Turn the steering to full loc k m om entarily, if the pressur e is below 7,580 k Pa (V6 engine) or 8,270 kPa (GEN III

V8 engine), a faulty hydraulic circuit is indicated.

TEST 2 - HYDRA ULIC CIRCUIT CLOSED

1. Slowly turn the valve on Tool E1461-1 to the c losed pos ition, note the pressure, and quickly re-open the valve to

avoid pump damage.

2. If the 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 k Pa (V6 engine) or 8,270 - 8,960 kPa ( GEN III V8 engine), the steer ing

gear, external hoses or connections may be considered faulty.

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

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

5. Install the high pressure line and O-ring to the pum p outlet fitting and tighten the flare nut to the correct torque

specification.

HIGH PRESSURE LINE FLARE NUT

TORQUE SPECIFICATION 25 – 35 Nm

6. While LIGHTLY holding the steering wheel on full lock, have an observer check for power steering 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 power steering fluid level correct? Go to Step 2. Top up as required

and check for leaks.

Go to Step 2.

2 • Check power steering fluid condition. Is power steering fluid

condition OK? Go to Step 3. Drain, flush system

and refill with power

steering 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 Gear

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 (GEN III 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 SOCKET

LT Section No. – 06-275

REPLACE

Tie rod sockets 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 the front of the vehicle and place on safety stands. Refer to Section 0A, GENERAL INFORMATION.

2. Rem ove the front wheel cover (steel wheels) or

centre caps (alloy wheels)

3. Mark the relationship of each wheel to

hub/brake disc. Remove the road wheel

attaching nuts and remove the wheels.

4. Remove the split pin and nut from the tie rod

ball stud.

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

centre screw to f orce the stud f rom the taper in

the steering arm.

6. Loosen the tie rod lock nut. Unscrew the socket

(1) from the tie rod, counting the number of

turns to wind the socket from the tie rod.

7. Install the new socket (1) onto the tie rod and

wind the nut on the same num ber of turns as in

Step 3.

8. Ins tall the soc ket to the steer ing arm. Install the

castellated nut and tighten to the corr ect torque

specification.

TIE ROD SOCKET STUD CASTELLATED

NUT TORQUE SPECIFICATION 50 – 85 Nm

NOTE: Ensure that the nylon spacer is positioned

on the tie rod socket stud before installing into the

steering arm.

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

Figure 9-40

10. Check the front wheel toe. Refer to

Section 3, FRONT SUSPENSION.

NOTE: Ensure the plastic spacers are positioned

on tie rod end ball studs and that they are in good

condition before fitting the studs into the steering

arms. Replace the spacers if damaged.

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

torque specifcation.

TIE ROD SOCKET LOCK NUT

TORQUE SPECIFICATION 50 – 85 Nm

12. Install the wheels, aligning the m arks m ade on

removal. Tighten wheel attaching nuts to the

correct torque specification. Do not over-

tighten!

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 – 140 Nm

13. Lower the vehicle to the ground and reconnect

the battery earth lead.

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

Section 3, FRONT SUSPENSION for details

3.6 RIGHT-HAND DRIVE POWER STEERING GEAR

LT Section No. – 06-275

NOTE: The following fasteners have either micro

encapsulation or incorporate a mechanical thread lock

and should only be used once. If in doubt, r eplacement

is recommended when performing this operation:

♦ Steering gear housing to front suspension

crossmember nuts.

♦ Steering coupling lower cam bolt nut.

NOTE: The following fasteners MUST be replaced

when performing this operation:

Steering gear pinion lower bearing retaining nut

IMPORTANT: Remove t he ignit ion key from the ig nition lock and ensu re that 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

1. Disconnect the battery earth lead.

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

3. Remove the front wheel cover (steel wheels) or centre caps (alloy wheels)

4. Mark the relationship of each wheel to the hub/brake disc. Remove the road wheel attaching nuts and rem ove

wheels.

5. Place a drain tray beneath the steering gear.

6. Loosen and remove the hydraulic lines (2 and

3) fr om the st eering gear valve housing (1) and

allow the power steering fluid to drain into a

suitable container.

Figure 9-41

7. Remove the steering coupling lower cam bolt

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

Figure 9-42

Techline

8. Remove the tie rod socket split pins and

castellated nuts (’3’ in Figure 9-58).

9. Separate the tie rod socket (1) studs from the

steering arm tapers using a suitable remover,

such as Tool No. 9A10.

Figure 9-43

10. Remove the steering gear housing to front

suspension crossmember mounting bolts (1)

and nuts (2).

11. Remove the s teering gear by pulling it out from

the front suspension crossmember mounting

(4) and slide pinion (input) shaft (5) from the

steering coupling lower clamp.

Figure 9-44

REINSTALL

NOTE 1: This is achieved by rotating the pinion to

the halfway position of its total lock to lock rotation.

When the G ear is in the s tr aight ahead pos ition, 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.

1. Ensure the steering gear is centralised.

2. Ensure the steering wheel is in the straight

ahead position.

3. Slide the steering gear pinion (input) shaft into

the steering coupling lower flange.

4. Position the steering gear housing into the

crossmember mounting points. Install the

mounting bolts, washers and nuts and tighten

the nuts to the correct torque specification.

(6)STEERING GEAR HOUSING TO

CROSSMEMBER MOUNTING NUT

TORQUE SPECIFICATION 60 Nm, then

40° - 50° turn

angle

5. Inspect the condition of the steering gear

hydraulic line O-rings. Replace as necessary.

6. fit the hydraulic lines to the steering gear valve

housing. Tighten the flare nuts to the correct

torque specification.

HYDRAULIC LINE TO VALVE

HOUSING FLARE NUT

TORQUE SPECIFICATION 30 – 42 Nm

Figure 9-45

7. Install the lower c am bolt (2) and a new nut (4).

Tighten to the correct torque specification.

(6)STEERING COUPLING CAM BOLT

TORQUE SPECIFICATION 25 – 30 Nm

8. Install the tie rod end ball studs into the steering

arms. Install the castellated nuts and tighten to

the correct torque specification.

TIE ROD SOCKET STUD

CASTELLATED NUT

TORQUE SPECIFICATION 50 – 85 Nm

9. Install new split pins.

NOTE: Ensure the plastic spacers are positioned

on the tie rod end ball studs and that they are in

good condition before fitting the studs into the

steering arms. Replace the spacers if damaged.

10. Install the wheels, aligning the marks made on

removal. Tighten the wheel attaching nuts to

the correct torque specification.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 – 140 Nm

11. Lower the vehicle to ground and reconnect the

battery earth lead.

Figure 9-46

12. Fill and bleed the hydraulic system, refer to 3.3, HYDRAULIC SYSTEM, BLEEDING/REFILLING in this

Section.

13. Check the front wheel toe-in setting, refer to Section 3, FRONT SUSPENSION for details.

DISASSEMBLE

CAUTION: During the manufacturing process, the threaded ends of the steering rack and piston assembly

are staked to the tie rod inner socket housing. Consequently, during disassembly of the power steering

gear, damage t o t he th reads on the end of the t ie rod inner socket and rack and pist on assembly will occur.

Whenever a steering gear is disassembled, the inner tie rods and the rack and piston assembly MUST be

replaced.

For identification of components, refer to Figure 9-51.

1. Clean all dirt and foreign matter from the exterior of the steering gear assembly.

2. Mount the steering gear hous ing (1) by gripping

the right-hand mounting boss in a vice fitted

with soft jaws (2).

3. Place a drain tray beneath the steering gear.

Figure 9-47

4. Unclip and remove all bellows clips.

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

the clips sideways until they disengage.

Figure 9-48

b. To rem ove the inner clips (1): Push out the pin

retaining the clip ends together using a fine pin

punch.

Figure 9-49

5. Loos en the tie r od lock nuts ( 2) and r emove the

outer tie rod sockets (3) and lock nuts (2) from

the tie rods (1).

6. Slide the bellows from the steering gear

housing and tie rods.

7. Rotate the pinion (input) shaft fully counter-

clockwise (full left lock).

Figure 9-50

Figure 9-51

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. Pinion Intermediate Roller Bearing

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. Sea, 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.

9. Using Tool No. 211-258, loosen then tighten

the tie rod socket housing (2) to break the

staking, then unscrew the housing from the end

of the rack.

CAUTION: During the manufacturing process,

the threaded ends of the steering rack and

piston assembly are staked to the tie rod inner

socket housing. Consequently, during

disassembly of the power steering gear,

damage to the threads on the end of the tie rod

inner socket and the rack and piston assembly

will occur. Whenever a steering gear is

disassembled, the inner tie rods and the rack

and piston assembly MUST be replaced.

10. Remove the housing assembly from the vice

and ensure that there is no foreign matter on

the rack teeth. Rotate the pinion (input) shaft

clockwise, just enough to expose the left-hand

tie rod socket housing.

11. Remount the steering gear in the vice, again

gripping on the right-hand end of the exposed

teeth of the rack.

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

the same method described in step 9.

Figure 9-52

13. Remount the steering gear housing (3) in the

vice fitted with protective jaws, gripping the

right-hand mounting boss.

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

valve housing (2) and the steering gear tubing

(3).

Figure 9-53

15. Rem ove the dust cover from the valve housing

and input shaft.

Figure 9-54

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 9-55

17. Remove the pinion lower bearing screw plug

(1) from the housing (2).

Figure 9-56

18. While holding the input pinion with a 15 m m s et

spanner across the flats, remove the pinion

lower bearing retaining nut from the pinion,

using a 17 mm socket and ratchet.

Figure 9-57

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

using Tool No. AU301.

20. Rotate the input shaft fully clockwise (full right

lock).

Figure 9-58

21. Loosen and remove the rack pad adjuster

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

Figure 9-59

22. Remove the r ack pad spring ( 1), plastic washer

and rack pad assembly from the 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 9-60

23. With the steering gear housing supported on

suitable pr ess plates such as E6673 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 9-61

24. Remove and discard the PTFE rings from the

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 s ubsequent internal leakage

could oc c ur, resulting in a heavy or inconsis tent

steering feel.

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 9-62

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

relative position of the left-hand mounting

bracket and the steering Gear tube (1).

Figure 9-63

26. 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 9-64

27. 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 bushing 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 9-65

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

over suitable press plates such as E6673 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 pressing 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 9-66

29. 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) from the rack housing.

Figure 9-67

30. Remove the 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 9-68

31. 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 9-69

32. 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 9-70

CLEAN AND INSPECT

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

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

2. Inspect the 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 the pinion for signs of tooth wear or damage.

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

6. Inspect the rack pad for damage or excessive wear.

7. Inspect the 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

CAUTION: During the manufacturing process, the threaded ends of the steering rack and piston assembly

are staked to the tie rod inner socket housing. Consequently, during disassembly of the power steering

gear, damage to the threads on the end of the tie rod inner socket and the rack and piston assembly will

occur. Whenever a steering gear is disassembled, the inner tie rods and the rack and piston assembly

MUST be replaced.

1. Check that each of the rack seals have a circular, plastic insert ring fitted to each, on the opposite side to the

spring loaded seal lip, with the tapered edge of the inser t facing in toward the seal. Ens ure the tapered ends of

the rings seat correctly.

2. Screw Tool No. AU460 onto driver handle T ool

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 automatic transmission 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 the seal into the rack housing (1) on top

of the spac er (3). T he seal will be fully installed

when the end of Tool No. AU355-A protrudes

from the rack tube by approximately 60 mm.

Figure 9-71

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

8. Af ter dipping a new Tef lon seal ring (1 ) in clean

power steering fluid, install the seal ring over

expander Tool No. E8803-9.

Figure 9-72

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 9-73

10. Ensure that the seal is seated correctly in the

groove, by wrapping f inger s ar ound the seal, as

shown.

Figure 9-74

11. Install the protector sleeve, Tool No. AU456

over the toothed end of the rack (1) 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 r ack

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 9-75

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 9-76

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 9-77

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 9-78

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 Tool

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 9-79

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 made prior to removal.

Figure 9-80

22. Centralise the rack assembly by measuring

82 ± 1mm from the lock stop (flange inside

rack housing) to the end of the toothed rack

(1), as shown.

Figure 9-81

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 9-82

25. Reverse Tool AU527 onto the 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 Gear

housing until fully seated. Remove the

installation tools.

Figure 9-83

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

grooves, first warm in hot water then install on

the expander, Tool No. 9A23.

Slide the expanding tool with the ring installed,

over the sleeve, then push the s eal off and into

the sleeve groove. Repeat for the remaining

three seals.

Figure 9-84

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 to 10

minutes to contract rings back to normal size.

Figure 9-85

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 the Gear in the centralised

position, insert the pinion s o that the c lamp bolt

flat of the input shaft is positioned as shown,

when the pinion is fully located in the housing.

Figure 9-86

31. Pack the pinion lower bearing with EP Semi

Fluid Lithium Base Grease.

32. Install 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 a 15 mm 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 the bearing is

installed.

Figure 9-87

33. Install the pinion lower bearing retaining nut

and tighten to the correct torque specification,

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 TORQUE SPECIFICATION 35 – 45 Nm

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 9-88

34. Lubricate the upper pinion roller bearing (1)

with Dexronâ III automatic transmission fluid,

then install the bearing over the pinion shaft.

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

Gear 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 9-89

36. Lubricate a new pinion shaft upper power

steering fluid seal (1) with Dexronâ III

automatic transmission fluid, then install the

seal over the pinion shaft with the seal lips

facing down.

37. Install the pinion shaft upper power steering

fluid 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 power steering fluid seal. When

the shoulder contacts the rack housing, the power

steering fluid seal will have been installed to the

correct depth.

Figure 9-90

38. Using suitable circlip pliers, install the circlip

over the top of the pinion upper power steering

fluid seal, ensuring that the circlip locates

correctly in the housing groove.

Figure 9-91

39. Apply Loctite 242 thread sealant (or equivalent

to Holden’s Specification HN1256) to the

cleaned threads of the pinion lower screw plug

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

tighten to the correct torque specification.

PINION LOWER RETAINING SCREW

PLUG TORQUE SPECIFICATION 55 – 60 Nm

Figure 9-92

40. Install the rack pad insert to the rack pad (if

removed). Install the rack pad assembly into

the steering gear housing.

41. Install the plastic washer (1) and the rack pad

spring (2).

Figure 9-93

42. Screw the lock nut onto the adjusting screw.

Install the adjusting screw (1) into the steering

gear housing, using Tool AU211-A but leave

the lock nut loose.

Figure 9-94

43. With the steering rack in the centralised

position, tighten the rack pad adjusting screw

(1) to the correct initial torque using Tool No.

AU211-A, a suitable socket (2) and a torque

wrench (3).

RACK PAD ADJUSTING SCREW

INITIAL TORQUE SPECIFICATION 10 – 12 Nm

Figure 9-95

44. Using an angle wrench and special tools E7115

and AU211-A, turn the rack pad adjusting

screw back (anti-clockwise) 20 - 28°.

Figure 9-96

45. Install Tool AU316 to the input shaft and

measure the rotating torque of the 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, m inor variations f rom spec ification

in rotating torque can be corrected by

readjusting the rack pad spring tension.

NOTE: If a large variation from specification in

rotating torque or binding is experienc ed, the cause

must be determined and corrected before

proceeding further.

Figure 9-97

47. Apply Loctite 242 thread sealant (or equivalent)

to the cleaned threads of the rack pad plug lock

nut.

48. While holding the adjusting screw in the

correctly adjusted position with Tool No.

AU211-A and a sock et bar, tighten the lock nut

(1) to the correct torque specification using

Tool No. AU301 and a torque wrench.

RACK PAD ADJUSTING SCREW LOCK

NUT TORQUE SPECIFICATION 55 – 65 Nm

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 the

gear bind or appear tight, recheck the rack pad

adjustment. If this is not the cause, disassemble

the gear assembly and examine the rack and

pinion for wear. Replace as necessary.

Figure 9-98

49. Reconnect the f eed pipes (1 and 4) to the valve

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

tighten the pipe flare nuts to the correct torque

specification.

FEED PIPE FLARE NUT

TORQUE SPECIFICATION 15 – 25 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.

50. Rotate the pinion shaft fully anti-clockwise (left

lock).

51. Remove the steering gear housing from the

vice, and grip the exposed toothed end of the

rack in the vice with soft jaws.

Figure 9-99

52. Using Tool No. 211-258, tighten the right-hand

tie rod to the correct torque specification.

TIE ROD TO RACK AND PISTON

ASSEMBLY TORQUE SPECIFICATION 90 – 100 Nm

CAUTION: During the manufacturing process,

the threaded ends of the steering rack and

piston assembly are staked to the tie rod inner

socket housing. Consequently, during

disassembly of the power steering gear,

damage to the threads on the end of the tie rod

inner socket and the rack and piston assembly

will occur. Whenever a steering gear is

disassembled, the inner tie rods and the rack

and piston assembly MUST be replaced.

53. Using the centre punch and a large ball-pein

hammer, stake the rack to tie rod socket

housing in two places inside the k ey-way at the

end of the rack.

NOTE: The key-way at either end of the steering

rack has not been hardened, and is the only area

that is suitable f or the stak ing procedure. Ens ure to

stak e the rack in two places as close as possible to

the tie-rod inner socket (either side of key way).

54. Remove the steering gear housing from the

vice and rotate the pinion shaft slightly

clockwise, just enough to expose the left-hand

end of the rack.

55. Tighten the left-hand tie rod as in steps 52 and

53.

56. Relocate the steering gear housing in the vice

by gripping the right-hand mounting boss.

57. Rotate the input shaft to the straight ahead

position.

Figure 9-100

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

ensuring that the cover is engaged with the

groove in the pinion.

Figure 9-101

59. Fit the bellows to the tie rods and steering gear housing. Install the retaining clips.

60. Fit the tie rod socket lock nuts and the tie rod sockets to the tie rods.

NOTE: Do not tighten the lock nuts, as toe adjustment must be performed after steering gear is installed.

61. Install the steering gear assembly into the vehicle, as detailed In 3.6 POWER STEERING GEAR - REINSTA LL.

3.7 LEFT-HAND DRIVE POWER STEERING GE AR

LT Section No. – 06-275

NOTE 1: The following fasteners have either micro

encapsulation or incorporate a mechanical thread lock

and should only be used once. If in doubt, r eplacement

is recommended when performing this operation:

♦ Steering gear housing to front suspension

crossmember nuts.

♦ Steering coupling lower cam bolt nut.

NOTE 2: The following fasteners MUST be replaced

when performing this operation:

Steering gear pinion lower bearing retaining nut

IMPORTANT: Remove the ignition key from the ignition lock and ensure that the steering column is locked. If this

operation is not car ried out and the steering wheel is spun while the steering gear is removed f rom the vehicle, the

clock spring coil in the upper end of the steering column will be destroyed!

REMOVE

1. Disconnect the battery earth lead.

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

3. Remove the front wheel cover (steel wheels) or centre caps (alloy wheels)

4. Mark the relationship of each wheel to the hub/brake disc. Remove the road wheel attaching nuts and rem ove

the wheels.

5. Place a drain tray beneath the steering gear.

6. Loosen and remove the hydraulic lines (2 and

3) fr om the st eering gear valve housing (1) and

allow the power steering fluid to drain into a

suitable container.

Figure 9-102

7. Remove the steering coupling (1) lower cam

bolt nut (2), rem ove the cam bolt (3), then s lide

the coupling away from the steering gear (4).

Figure 9-103

Techline

8. Remove the tie rod end split pins and

castellated nuts (’3’ in Figure 9-105).

9. Separate the tie rod end ball studs (1) from

steering arm tapers using a suitable remover,

such as Tool No. 9A10.

Figure 9-104

10. Remove the steering gear housing to front

suspension crossmember mounting bolts (1)

and nuts (2).

11. Remove the s teering gear by pulling it out from

the front suspension crossmember mounting

(4) and slide the pinion (input) shaft (5) from

the steering coupling lower clamp.

Figure 9-105

REINSTALL

1. Ensure that the steering gear is centralised.

NOTE: This is achieved by rotating the pinion to the

halfway position of its total lock-to-lock rotation.

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

flat on the pinion (input) shaft (1) will be aligned as

shown in Figure 9-106.

NOTE: 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 that the st eering wheel is in the straight

ahead position.

3. Slide the steering gear pinion (input) shaft into

the steering coupling lower flange.

4. Position the steering gear housing into the

crossmember mounting points. Install the

mounting bolts, washers and nuts and tighten

the nuts to the correct torque specification.

(6)STEERING GEAR HOUSING TO

CROSSMEMBER MOUNTING NUT

TORQUE SPECIFICATION 60 Nm, then

40° - 50° turn

angle

5. Inspect the condition of the steering gear

hydraulic line O-rings. Replace as necessary.

6. Fit hydraulic lines to the steering gear valve

housing. Tighten the flare nuts to the correct

torque specification.

Figure 9-106

7. Ins tall the lower cam bolt (3) and a new nut (2).

Tighten to the correct torque specification.

(6)STEERING COUPLING CAM BOLT

NUT TORQUE SPECIFICATION 25 – 30 Nm

8. Install the tie rod end ball studs into steering

arms. Install castellated nuts and tighten to the

correct torque specification.

TIE ROD SOCKET STUD

CASTELLATED NUT

TORQUE SPECIFICATION 50 – 85 Nm

9. Install new split pins into the tie rod ball studs.

NOTE: Ensure that the plastic spacers are

positioned on tie rod end ball studs and that they

are in good condition before fitting the studs into

the steering arms. Replace the spacers if

damaged.

Figure 9-107

10. Install the wheels, aligning the m arks m ade on removal. T ighten the wheel attaching nuts to the correct torque

specification.

ROAD WHEEL ATTACHING NUT

TORQUE SPECIFICATION 110 – 140 Nm

11. Lower the vehicle to the ground and reconnect the battery earth lead.

12. Refill and bleed the hydraulic system, refer to 3.3, HYDRAULIC SYSTEM, BLEEDING/REFILLING in this

Section.

13. Check the front wheel toe setting, refer to Section 3, FRONT SUSPENSION.

Figure 9-108

Legend for Figure 9-108

1. Screw, Valve Housing (2 places)

2. Cover, Dust

3. Housing, Valve

4. O-ring

5. Seal

6. Bearing, Roller

7. Circlip

8. Valve Assembly, Rotary

9. Seal

10. Bearing, Roller

11. Bearing, Ball

12. Nut, Pinion

13. Plug, Sealing

14. Insert, Rack Pad

15. Pad, Rack

16. Washer

17. Spring

18. Plug, Rack Pad

19. Nut, Lock

20. Housing, Steering Gear

21. Pipe, Rack Piston Fluid - Short

22. Pipe, Rack Piston Fluid - Long

23. Rack and Piston Assembly

24. Spacer, Inner Rack Seal

25. Seal, Inner Rack

26. Seal, Rack Piston

27. O-ring, Rack Piston

28. Seal, Outer Rack

29. Bushing, Rack Outer

30. Wire, Retaining

31. Rod, Tie

32. End, Tie Rod

33. Nut, Lock

34. Bellows

35. Clip, Bellows Outer

36. Tie Strap, Bellows Inner Tie

37. Bracket, Mounting

38. Insulator, Mounting Bracket

DISASSEMBLE

CAUTION: During the manufacturing process, the threaded ends of the steering rack and piston assembly

are staked to the tie rod inner socket housing. Consequently, during disassembly of the power steering

gear, damage t o t he th reads on the end of the t ie rod inner socket and rack and pist on assembly will occur.

Whenever a steering gear is disassembled, the inner tie rods and the rack and piston assembly MUST be

replaced.

For identification of components, refer to Figure 9-108.

1. Clean all dirt and foreign matter from the exterior of the steering gear assembly.

2. Mount the steering gear hous ing (1) by gripping

the left-hand mounting boss (2) in a vice fitted

with soft jaws.

3. Place a drain tray beneath the steering gear.

Figure 9-109

4. Unclip and remove all bellows clips.

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

clips sideways until they disengage.

Figure 9-110

b. T o remove the inner clips (1): Push out the pin

retaining the clip ends together using a fine pin

punch.

Figure 9-111

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

rod sockets (3) and lock nuts (2) from the tie

rods (1).

6. Slide the bellows from the steering gear

housing and tie rods.

7. Rotate the pinion (input) shaft fully clockwise

(full right lock).

Figure 9-112

8. Remove the steering gear housing from the

vice and grip the expos ed tooth end of the rac k

(1) in a vice with soft jaws.

Figure 9-113

9. Using Tool No. 211-258, loosen then tighten

the left-hand tie rod inner socket housing to

break the staking, then unscrew the housing

from the end of the rack.

Figure 9-114

10. Remove the housing assembly from the vice and ensure that there is no foreign matter on the rack teeth.

Rotate the pinion (input) shaft counter-clockwise, (full left lock) to expose the rack and tie rod inner socket

housing.

11. Remount the steering gear in the vice, gripping around the exposed end of the rack.

12. Remove the left-hand tie rod assembly as in step 9.

13. Remount the steering gear housing (3) in the

vice fitted with protective jaws, gripping the

right-hand mounting boss.

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

valve housing (2) and the steering gear tubing

(3).

Figure 9-115

15. Rem ove the dust cover from the valve housing

and input shaft.

Figure 9-116

16. Using a 5 mm Allen key, remove the valve

housing attaching screws (3). Withdraw the

valve housing (2) from the input shaft.

Figure 9-117

17. Remove and discard the valve housing to

steering gear housing O-ring (1).

Figure 9-118

18. Place the flange f ace of the valve housing onto

a wooden block and, using Tool No. AU314,

drive the valve seal and bearing from the valve

housing.

Figure 9-119

19. Remove the pinion lower bearing screw plug

(1) from the housing.

Figure 9-120

20. While holding the input pinion with a set

spanner across the flats, remove the pinion

lower bearing retaining nut from the pinion.

Figure 9-121

21. Remove the rack pad adjuster lock nut (1)

using Tool No. AU301.

22. Rotate the input shaft fully clockwise (full right

lock).

Figure 9-122

23. Loosen and remove the rack pad adjuster

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

Figure 9-123

24. Remove the rack pad spring (1) and rack pad

assembly from the steering gear housing.

NOTE: The rack pad assembly may be assisted

from the steering gear housing with a pair of

internal c irclip pliers, however, it may be necessary

to rem ove the housing from the vice and tap gently

on a wooden block to dislodge the rack pad

assembly.

Figure 9-124

25. Using a brass drift (1) and a soft faced

hammer, gently knock on the lower end of the

pinion to remove the pinion assembly from the

housing.

Figure 9-125

26. Using a large screwdriver, lever out the pinion

seal (1) from the housing (2). Discard the seal.

NOTE: Take care not to damage the housing lip.

Figure 9-126

27. Remove and discard the PTFE rings from the

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 s ubsequent internal leakage

may occur, resulting in heavy or inconsistent

steering feel.

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 9-127

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

relative position of the left-hand mounting

bracket and the steering rack tube (1).

Figure 9-128

29. 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 9-129

30. Remove the rack end bushing retaining wire,

as follows:

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

extension and bar, rotate 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

bushing with Tool No. E8803-7, in a clockwise

direction (ar row), winding the retainer out of the

tube.

c. Continue unwinding the retainer until the end of

the retainer (1) appears , then lif t it fr om the slot

in the rack tube.

Figure 9-130

31. Remove the rack from the housing by using a

brass drift on the left-hand end of the rack and

driving the rack out the tube end of the rack

housing.

NOTE: As this action will remove the rack end bush

and the outer piston rod seal from the steering

tube, some resistance will be encountered. If

necessary, a suitable hydraulic press may be used.

Figure 9-131

32. 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 to

drive the spacer (2) and inner piston rod seal

(3) and from the rack housing.

Figure 9-132

33. Remove the pinion lower bearing using Tool

No. AU306 and driver handle AU355-A.

NOTE: The pinion upper bearing cannot be

removed from the steering gear housing. If the

upper bearing is found to be damaged or has

failed, then the housing and bearing assembly must

be replaced.

Figure 9-133

34. Remove the 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 9-134

CLEAN AND INSPECT

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

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

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

NOTE: The pinion upper bearing cannot be rem oved from the steering gear housing. If the upper bearing is found

to be damaged, replace the housing and pinion upper bearing assembly.

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

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

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

5. Ins pec t the hous ing f or wear or damage in the pinion bearing bores , the s eal bores , the r ack piston and the loc k

stop faces.

6. Inspect the rack pad for damage or excessive wear.

7. Inspect the major components of the 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 fitted to each, on the opposite side to the

spring loaded seal lip, with the tapered edge of the inser t facing in toward the seal. Ens ure the tapered ends of

the rings seat correctly.

2. Screw Tool No. AU460 onto the 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

spacer in plac e. Ins ert the tools and s pac er 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 automatic transmission 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 the seal into the rack housing (1) on top

of the spac er (3). T he seal will be fully installed

when the end of Tool No. AU355-A protrudes

from the rack tube by approximately 60 mm.

Figure 9-135

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

8. Af ter dipping a new Tef lon seal ring (1 ) in clean

power steering fluid, install the seal ring over

expander Tool No. E8803-9.

Figure 9-136

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 9-137

10. Ensure that the seal is seated correctly in the

groove, by wrapping f inger s ar ound the seal, as

shown.

Figure 9-138

11. Install the protector sleeve, Tool No. AU456

over the toothed end of the rack (1) 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 r ack

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 9-139

14. Again install 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, then install

the seal over the protector and onto the rack,

with the seal lips facing in towards the rack

piston.

Figure 9-140

15. Lubricate the left-hand end bearing, inner

surface, with clean power steering fluid, then

install the end bearing into the rack tube,

pushing in against the outer rack seal.

NOTE: To assist with installation of the bearing

retaining wire, align the hole in the bearing with the

opening in the steering housing tube.

16. Using a suitable diameter piece of tubing, tap

the seal and bearing into the rac k tube until the

retaining wire groove in the bearing, is aligned

with the slot in the rack housing tubing.

Figure 9-141

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 9-142

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

cylinder pipe fittings. Tighten the unions just

sufficient 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 9-143

21. Check the mounting bracket insulator for

serviceability. Apply petroleum j elly (Vaseline or

equivalent) to the inner surf ace, then install the

brack et and insulator on to the steering tube, in

the reverse manner to removal. Align the

marks made prior to removal.

Figure 9-144

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 9-145

23. Lubricate a new pinion upper seal with Dex ronâ

III automatic transm ission fluid, then f it the seal

to Tool No. AU315, that has driver handle

AU355-A attached. Press seal into place in the

valve housing (1).

24. Lubricate the upper pinion bearing with EP

Semi Fluid Lithium Base O Grease and fit to

Tool No. AU315, that has driver handle AU355-

A attached. Press the bearing into the valve

housing until the bearing is fully seated.

Figure 9-146

25. To fit new PTFE seal rings (1) into the sleeve

grooves, first warm in hot water then install

each s eal ring, in tur n, on to the expander , T ool

No. 9A23.

Slide expanding tool with ring installed, over the

sleeve, then push the seal off and into the

sleeve groove. Repeat for the remaining three

seals.

Figure 9-147

26. After all the seals have been fitted to the sleeve

grooves, push Tool No. AU440 over the rings

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

minutes to contract rings back to normal size.

Figure 9-148

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

O Grease into the steering gear housing,

through the pinion bore.

28. Using Tool No. AU313, install a new seal into

the steering gear housing (1), fully seating the

seal in its bore.

Figure 9-149

29. While maintaining the rack in the centralised

position, insert the pinion s o that the c lamp bolt

flat (1) of the input shaft is positioned as

shown, when the pinion is fully located in the

housing.

Figure 9-150

30. Pack the pinion lower bearing with EP Semi

Fluid Lithium Base Grease. Install the pinion

lower bearing using Tool No. AU307.

NOTE: Tool No. AU307 screws onto the end of

pinion and pinion lower bearing is fully installed

when Tool No. AU307 cannot be screwed onto the

pinion any further. Remove AU307 once bearing is

installed.

Figure 9-151

31. Install rack pad insert into the rack pad. Install

the rack pad assembly into the steering gear

housing.

32. Install the rack pad spring (1) and the plastic

washer.

Figure 9-152

33. Screw the lock nut onto the adjusting screw.

Install the adjusting screw into the steering

gear housing. Leave lock nut loose.

34. Install the pinion lower bearing retaining nut

and tighten to the correct torque specification.

(+)PINION LOWER BEARING RETAINING

NUT TORQUE SPECIFICATION 35 – 45 Nm

NOTE: T his is a def orm ed thread loc k nut and m ay

be reused once only. However, it is recommended

that a new nut is fitted at each overhaul.

Figure 9-153

35. Apply Loctite 242 thread sealant (or equivalent)

to the cleaned threads of the pinion lower

screw plug and tighten to the correct torque

specification.

PINION LOWER RETAINING SCREW

PLUG TORQUE SPECIFICATION 55 – 60 Nm

Figure 9-154

36. Install a new O-ring (2) onto the lip of the

steering gear housing (1).

Figure 9-155

37. Slide the valve housing (2) over the input shaft

and locate the valve housing onto the lip of the

steering gear housing (1).

NOTE: Care must be taken to ensure that the

PTFE sleeve seals and valve seal are not cut or

deformed during this process.

38. Install and tighten the valve housing retaining

screws (3) to the correct torque specification.

VALVE HOUSING RETAINING

SCREW TORQUE SPECIFICATION 5 – 6 Nm

Figure 9-156

39. Reconnect the f eed pipes (1 and 4) to the valve

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

tighten the pipe flare nuts to the correct torque

specification.

FEED PIPE FLARE NUT

TORQUE SPECIFICATION 15 – 25 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 9-157

40. With the steering rack in the centralised

position, tighten the rack pad adjusting screw

(1) using Tool No. AU211-A to the specified

torque.

RACK PAD ADJUSTING SCREW

TORQUE SPECIFICATION 10 – 12 Nm

Figure 9-158

41. Using angle wrench, Tool No. E7115 and

adaptor, T ool AU211-A, tur n rack pad adjus ting

screw back (anti-clockwise) 20 - 28°.

Figure 9-159

42. Install T ool No. AU316 onto the input shaf t and

measure the rotating torque of the 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.

Figure 9-160

43. Apply Loctite 242 thread sealant (or equivalent)

to the cleaned threads of the rack pad plug lock

nut (1).

44. While holding the adjusting screw in the

position set at step 41 with Tool No. AU211-A

and a socket bar, tighten the lock nut to the

correct torque specification using Tool No.

AU301 and a torque wrench.

RACK PAD ADJUSTING SCREW LOCK

NUT TORQUE SPECIFICATION 55 – 65 Nm

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 the

gear bind or appear tight, recheck the rack pad

adjustment. If this is not the cause, strip the gear

assembly and examine the rack and pinion for

wear. Replace as necessary.

Figure 9-161

45. Rotate the pinion shaft fully anti-clockwise (left

lock).

46. Remove the steering gear housing from the

vice, and grip the exposed toothed end of the

rack in a vice with soft jaws.

CAUTION: During the manufacturing process,

the threaded ends of the steering rack and

piston assembly are staked to the tie rod inner

socket housing. Consequently, during

disassembly of the power steering gear,

damage to the threads on the end of the tie rod

inner socket and the rack and piston assembly

will occur. Whenever a steering gear is

disassembled, the inner tie rods and the rack

and piston assembly MUST be replaced.

47. Using Tool No. 211-258, tighten the left-hand

tie rod to the correct torque specification.

TIE ROD END HOUSING

TORQUE SPECIFICATION 90 – 100 Nm

48. Using a centre punch and a large ball-pein

hammer, stake the rack to the tie rod socket

housing in two places inside the k ey-way at the

end of the rack.

Figure 9-162

NOTE: The key-way at either end of the steering rack has not been hardened, and is the only area that is

suitable for the st ak ing pr oc edure. Ens ur e to stake the rac k in two places as c los e as poss ible to the tie-rod inner

socket (either side of key way).

49. Remove the s teering gear hous ing from the vic e and rotate the pinion shaf t slightly clockwise, j ust enough to

expose the right-hand end of the rack.

50. Tighten the left-hand tie rod as in steps 47 and 48.

51. Relocate the steering gear housing in the vice by gripping the right-hand mounting boss.

52. Rotate the input shaft to the straight ahead position. Install the dust cover onto the input shaft.

53. Fit bellows to the tie rods and steering gear housing. Install the retaining clips.

54. Fit the tie rod socket lock nuts and the tie rod sockets to the tie rods.

NOTE: Do not tighten the lock nuts, as a toe-in adjustment must be performed when the steering gear is

installed.

3.8 POWER STEERING FLUID RESERVOIR - V6 ENGINE

LT Section No. – 06-400

REMOVE

1. Place a drain tray beneath the reservoir assembly.

2. Loosen the hose clamps and remove the two

hoses from the reservoir.

NOTE: Cover or tape the hose ends to prevent

foreign matter entry.

Figure 9-163

3. Us ing a s uitable lever (1) s uch as a screwdriver

(2), gently lever locking tang back towards the

radiator and lift the reservoir (4) up and out of

the retaining bracket (3).

4. If required, remove the two hexagon headed

screws and one s elf tapping s c rew securing the

bracket to the radiator, then remove the

bracket.

Figure 9-164

REINSTALL

Installation is the reverse of the removal

operations, noting the following points:

1. Tighten the reservoir retaining bracket screws

to the correct torque specification.

RESERVOIR RETAINING BRACKET

ATTACHING SCREW

TORQUE SPECIFICATION 3 – 7 Nm

2. Refill and bleed the hydraulic system. Refer to

3.3 HYDRAULIC SYSTEM -

BLEEDING/REFILLING in this Section.

3. Start the engine and check for power steering

fluid leaks from the reservoir area.

Techline

3.9 POWER STEERING FLUID RESERVOIR - GEN III V8 ENGINE

LT Section No. – 06-400

REMOVE

1. Disconnect the battery earth lead from the

battery.

2. Remove the engine trim cover retaining nuts

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

Figure -165

3. Place a drain tray beneath the reservoir

assembly.

4. Loosen the hose clamps and remove the two

hoses from the reservoir.

NOTE: Cover or tape the hose ends to prevent

foreign matter entry.

Figure 9-166

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 9-167

REINSTALL

Installation is the reverse of the removal operations, noting the following:

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

RESERVOIR/ENGINE LIFT

BRACKET ATTACHING BOLT

TORQUE SPECIFICATION 50 Nm

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

POWER STEERING RESERVOIR

HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

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

ENGINE TRIM COVER NUT

TORQUE SPECIFICATION 8 – 12 Nm

4. Refill and bleed the hydraulic system. Refer to 3.3 HYDRAULIC SYSTEM - BLEEDING/REFILLING in this

Section.

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

3.10 POWER STEERING PUMP - V6 ENGINE

LT Section No. – 06-400

REMOVE

1. Disconnect the battery earth lead.

2. Loosen the four power steering pump pulley

attaching bolts (Do not remove at this stage).

3. Using a 15 mm ring spanner on the drive belt

tensioner pulley pivot bolt, rotate the tensioner

pulley anti-clockwise and rem ove the drive belt

from the pump pulley. Release the tensioner

pulley.

4. Remove the pump pulley attaching bolts and

the pulley from the pump .

Figure 9-168

6. Place a drain tray beneath the power steering

pump assembly.

7. Loos en and rem ove the high pres sure line f lare

nut (1) and O-ring (2) from the pump outlet

fitting.

8. Loosen the low pressure hose clamp (3) and

remove the hose from the reservoir.

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

prevent foreign matter entry.

Figure 9-169

9. Rem ove the two power steering pum p retaining

bolts (1) and remove the pump assembly (2)

from the retaining bracket (3).

10. If required, remove the two bolts (4) securing

the retaining brack et to the cylinder block , then

remove the bracket.

Figure 9-170

REINSTALL

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

1. Tighten the retaining bracket to cylinder block retaining bolts to the correct torque specification.

PUMP RETAINING BRACKET BOLT

TORQUE SPECIFICATION 30 – 40 Nm

2. Tighten the two pump to retaining bracket attaching bolts to the correct torque specification.

PUMP TO RETAINING BRACKET BOLT

TORQUE SPECIFICATION 30 – 40 Nm

3. Tighten the four pump pulley attaching bolts to the correct torque specification.

PUMP PULLEY BOLT

TORQUE SPECIFICATION 20 – 30 Nm

4. Install the new sealing O -ring on to the high pres sure line connection. Lubricate the sealing ring with Dexron® III

automatic transmission fluid prior to installation.

5. Refill and bleed the hydraulic system, refer to 3.3 HYDRAULIC SYSTEM - BLEEDING/REFILLING in this

Section.

6. Start the engine and check for power steering fluid leaks around the pump and reservoir area.

Figure 9-171

Legend

1. Shaft, Pump Drive

2. Seal, Pump Drive Shaft

3. Housing Assembly, Pump

4. Spring, Flow Control Valve

5. Valve, Flow Control

6. O-Ring, Outlet Fitting

7. Fitting, Outlet

8. O-Rings, Pressure and End

Plates

9. Dowel Pins, Pump Ring

10. Plate, Thrust

11. Rotor

12. Ring, Shaft Retaining

13. Vanes, Pump

14. Ring, Pump

15. Plate, Pressure

16. Spring, Pressure Plate

17. Plate, End

18. Ring, End Plate Retaining

DISASSEMBLE

1. Tilt the pum p assem bly up and allow the power

steering fluid to drain from the pump.

2. Remove the drive belt pulley hub, refer to

3.12, POWER STEERING PUMP PULLEY

HUB - V6 ENGINE in this Section.

3. Clamp the pump, with the rear surface

uppermost, in vice fitted with soft jaws. Do not

use excessive force or the pump body will be

distorted.

4. Remove the outlet f itting ( 1) and the as soc iated

O-ring. Take care as the spring loaded flow

control valve will thrust the outlet fitting from the

pump housing.

Figure 9-172

5. Compress the end plate retaining ring (1) by

pushing with a small punch through the hole in

pump housing, then remove the ring with a

screwdriver, ensuring to hold a hand over ring

as the end plate (2) is spring loaded and may

spring out.

NOTE: It may be necessary to slide the retaining

ring around with a screwdriver, until one end is

close to the access hole.

Figure 9-173

6. Remove the end plate. A slight rocking motion

or light tapping with a soft faced hammer will

force the plate if it should stick.

7. Remove the end plate spring (1).

8. Remove the end plate O-ring (2) from the

pump housing (3) and discard.

9. Remove the pump from the vice and invert to

remove the flow control valve and spring.

10. Clean the exposed end of the drive shaft to

remove any dirt or rust. This will prevent

damage to the shaft bush that might require the

housing to be replaced.

Figure 9-174

11. Us ing a suitable sof t fac ed ham m er (1), tap the

pump shaft (2) very lightly until the shaft,

pressure plate, pump ring, rotor assembly and

thrust plate can be removed as a unit.

12. Disassemble the parts just removed. Refer to

Figure 9-185 for relationship details. Remove

the vanes from the rotor. Remove the rotor

from the shaft after removing retaining ring

from shaft. Discard ring.

Figure 9-175

13. Remove the pressure plate O-ring (1) from the

pump housing (2) and discard.

14. Remove the dowel pins (3).

Figure 9-176

15. Prise the shaft seal (1) from the pum p housing

(2) with a screwdriver. Take care not to

damage the housing bore. Discard seal.

Figure 9-177

CLEAN AND INSPECT

Clean all metal parts in solvent, air dry and inspect as follows:

1. The flow control valve must slide freely in the housing bore. If sticking is observed, check for dirt and burrs.

2. Check the cap screw in end of the flow control valve for looseness: if loose, tighten, being careful not to damage

the machined surfaces.

3. Be sure that the pressure plate and thrust plate surfaces are flat and parallel with the pump ring. Check for

cracks and scoring.

NOTE: A high polish is always present on the rotor, pressure plate and thrust plate as a result of norm al wear. Do

not confuse this with scoring.

4. Ensure the vanes move freely in the rotor slots.

5. If the flow control plunger is suspected of being faulty, install a new component. T his part is serviced as a unit

only and is factory calibrated.

6. Check the drive shaft for worn splines, breaks, bush material pick-up, etc.

7. Using a piece of wire, probe through shaft seal relief hole to check for blockage.

8. Always replace all seals and O-rings when the pump is disassembled.

REASSEMBLE

1. Install a new shaft seal (1) in to the pump

housing using Tool No. E1460-1 or 96A1 (2).

Lubricate the seal lips with Dexron® III

automatic transmission fluid.

Figure 9-178

2. Install the thrust plate (1) on to the shaft (2)

with the ported face towards the splined end of

the shaft.

Figure 9-179

3. Install the rotor, which must be free on the shaft splines, with the countersunk side towards the thrust plate.

4. Install a new shaft retaining ring. Place the ring on the end of the shaf t and use a 10 m m s ocket to tap the ring

into place. Ensure the ring is correctly seated in the groove.

I Do not use a C-ring to replace the full circumference clip ring.

5. Install the dowel pins in to the pump housing.

6. Lubr icate the new pressure plate O-r ing with Dexr on® III autom atic trans miss ion fluid and install in to the pum p

housing.

7. Clamp pump housing, cavity uppermost, in a vice with soft jaws. Do not clamp with excessive force.

8. Ins tall the s haf t, thr us t plate and rotor assembly

into the housing, aligning the dowel pins (1)

with the thrust plate holes (2).

Figure 9-180

9. Install the pump ring onto the dowel pins with

the identifying three dots (arrow) facing

uppermost. There are four holes in the pump

ring, the smaller holes are the dowel pin holes.

10. Install the vanes into the rotor slots.

11. Lubricate the outer circum ference and c hamfer

of the pres sure plate with Dexron® III automatic

transmission fluid to prevent damage to the O-

ring. Install the pressure plate on to the dowel

pins with the ported face toward the pump ring

such that the narrow slots engage the dowel

pins.

12. Seat the pressure plate by placing a large

socket on top of the plate and pressing down

by hand. Plate will travel approximately 2 mm

to seat.

13. Install the pressure plate spring on to the

pressure plate.

14. Lubricate the new end plate O-ring with

Dexron® III automatic transmission fluid and

install the O-ring in to the housing groove.

Figure 9-181

15. Lubr icate the outside circ um fer ence and cham f er of the end plate with transm ission f luid to avoid dam aging the

O-ring and install the end plate.

16. Install the end plate retaining ring. Locate the end of the ring near the hole in the housing.

17. Install the flow control spring and plunger (hex head end first) into the pump housing.

18. Lubricate the outlet fitting O-ring with

transmission fluid, install the O-ring on to the

outlet fitting. Install the outlet fitting and tighten

to the correct torque specification.

POWER STEERING PUMP OUTLET

FITTING TORQUE SPECIFICATION 50 – 102 Nm

19. Install the pump pulley hub, refer to

3.12 POWER STEERING PUMP PULLEY

HUB - V6 ENGINE in this Section.

Figure 9-182

3.11 POWER STEERING PUMP - GEN III V8 ENGINE

LT Section No. – 06-400

REMOVE

1. Loosen the two hose clamps securing the air

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

Flow (MAF) sensor.

2. Remove the air intake duct from the throttle

body and MAF sensor.

3. Rem ove the engine acc essory drive belt. Refer

to Section 6A3, 2.6 ENGINE DRIVE BELTS.

Figure 9-183

4. Place a drain tray beneath the power steering

pump assembly.

5. Remove the power steering fluid reservoir.

Refer to 3.9 POWER STEERING FLUID

RESERVOIR - GEN III V8 ENGINE in this

Section.

6. Loosen and r em ove the high press ure line f lare

nut (1) and O-ring (2) from the pump outlet

fitting.

7. Loosen the low pressure hose clamp (3) and

remove the hose from the pump inlet fitting.

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

prevent foreign matter entry.

Figure 9-184

8. Rem ove 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 9-185

REINSTALL

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

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

PUMP TO CYLINDER HEAD BOLT

TORQUE SPECIFICATION 20 – 35 Nm

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

automatic transmission fluid prior to installation.

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

up spanner on the outlet fitting.

HIGH PRESSURE LINE FLARE NUT

TORQUE SPECIFICATION 25 – 35 Nm

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

LOW PRESSURE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

5. Install the power steering fluid reservoir. Refer to 3.9 POWER STEERING FLUID RESERVOIR - GEN III V8

ENGINE in this Section.

6. Install the engine accessory drive belt. Refer to Section 6A3, 2.6 ENGINE DRIVE BELTS.

1. Ins tall the air intak e duct to the thr ottle body and MAF sensor and tighten the hose clam ps to the correc t torque

specification.

AIR INTAKE DUCT HOSE CLAMP

TORQUE SPECIFICATION 5 – 8 Nm

2. Install the engine trim cover and the retaining nuts and tighten to the correct torque specification.

ENGINE TRIM COVER NUT

TORQUE SPECIFICATION 8 – 12 Nm

9. Refill and bleed the hydraulic system, refer to 3.3 HYDRAULIC SYSTEM - BLEEDING/REFILLING in this

Section.

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

INSPECTION AND OVERHAUL PROCEDURES

The disassem ble, clean, inspect and reas semble proc edures for the power steer ing pump as f itted to MY 2003 VY

and V2 Series Models fitted with the GEN III V8 engine are the same as the procedures for the power steering

pump as fitted to vehicles fitted with the V6 engine. For the necessary procedures to disassemble, clean, inspect

and reassemble the power steering pump for vehicles fitted with the GEN III V8 engine, refer to

3.10 POWER STEERING PUMP - V6 ENGINE in this Section.

3.12 POWER STEERING PUMP PULLEY HUB - V6 ENGINE

LT Section No. – 06-400

REPLACE

1. Remove the power steering pump, refer to

3.10 POWER STEERING PUMP – V6 ENGINE

in this Section.

2. Using suitable press plates, such as Tool No.

E6673, support the pulley hub (1) and press

down on the pump shaft (2) to remove the pump

assembly from the pulley hub.

Figure 9-186

3. Make sure the pulley hub bore and the pump

shaft are free from burrs. Place pulley hub on

end of pump shaft and install replacer, Tool No.

E9239A, by screwing the bolt fully into the pump

shaft.

Figure 9-187

4. Install the pulley hub by holding the bolt and

turning the large bearing nut clockwise.

Assemble the hub to the pump shaft until

dimension A equals 128.0 ± 0.3 mm.

5. Remove Tool No. E9239.

Figure 9-188

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

LT Section No. – 06-400

REPLACE – USING TOOL A U188 & E9239

1. Remove the power steering pump, refer to

3.11 POWER STEERING PUMP - GEN III V8

ENGINE in this Section.

2. Install suitable press plates, such as E6673

under the power steering pump pulley (1) with

pulley pr ess plates, T ool AU188 in between the

two and pres s the pump ass embly (2) from the

pulley, using a suitable sized drift on the pump

pulley shaft.

NOTE: Do not position the press plates on the

edge of the pulley, as damage to the pulley will

occur.

Figure 9-189

3. Ensure the pulley bore and the pump pulley

shaft are free of burrs, place pulley on end of

pump shaft.

4. Install Tool No. E9239 (or J25033-B) by

screwing the bolt fully into the pump pulley

shaft.

5. Install the pulley by holding the bolt head and

turning the large nut and bearing clockwise

until the pulley is flush with the shaft end.

6. Remove Tool No. E9239 (or J25033-B).

7. Install the power steering pump, refer to

3.11 POWER STEERING PUMP – GEN III V8

ENGINE in this Section.

Figure 9-190

Techline

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

LT Section No. – 06-400

REPLACE – USING TOOL 7185 & 7005

1. Remove the power steering pump, refer to

3.11 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 forc ing screw. Ensure that

the 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 9-191

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

onto the forcing screw of 7005 – POWER

STEERING PULLEY REPLACER as shown in

fig 9.198. Ensure that 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. Turn the dr ive nut (1) agains t 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. O nce the pulley is installed, r emove the fo rcing

screw from the pump shaft.

9. Install the power steering pump, refer to

3.11 POWER STEERING PUMP – GEN III V8

ENGINE in this Section.

Figure 9-192

Techline

3.15 RIGHT-HAND DRIVE POWER STEERING FLUID COOLE R AND

HOSE/PIPE ROUTING – V6 ENGINE

LT Section No. – 06-400

ARRANGEMENT

Refer to F igure 9-193 f or the general layout of the power steering f luid cooler, hoses and fittings us ed for the power

steering fitted to right-hand drive MY 2003 VY and V2 Series Vehicles fitted with a V6 engine.

Figure 9-193

Legend

1. High Pressure Hose

2. Fluid Cooler Pipe

3. Pump Mounting Bracket

4. Pump Assembly

5. Pressure Pipe and Hose

6. Pump Hub

7. Pump Pulley

8 O-Ring – Power Steering Pipe

(2 places)

9. Return Pipe

10. Pressure Pipe

11. Hose Clamp (3 places)

12. Low Pressure Hose

3.16 LEFT-HAND DRIVE POWER STEERING FLUID COOLER AND

HOSE/PIPE ROUTING – V6 ENGINE

LT Section No. – 06-400

ARRANGEMENT

Refer to F igure 9-194 f or the general layout of the power steering f luid cooler, hoses and fittings us ed for the power

steering fitted to left-hand drive MY 2003 VY and V2 Series Vehicles fitted with a V6 engine.

Figure 9-194

Legend

1. Low Pressure Fluid Return Hose, Cooler to Reservoir

2. High Pressure Fluid Feed Pipe Assembly, Pump to

Gear

3. Low Pressure Fluid Return Pipe, Gear to Cooler

4. Clamp, Fluid Cooler Hose to Low Pressure Return Pipe

5. O-Ring, Pipe to Steering Gear (2 places)

6. Cooler, Power Steering Fluid

3.17 RIGHT-HAND DRIVE POWER STEERING FLUID COOLE R AND

HOSE/PIPE ROUTING - GEN III V8 ENGINE

LT Section No. – 06-400

ARRANGEMENT

Refer to Figures 9-195 and 9-196 for the general arrangement of the power steering fluid 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.

Figure 9-195

Legend

1. Power Steering Rack

2. O-ring, Fluid Pipe to Rack

3. Flare Nut, Fluid Pipe (2 places)

4. Pipe, Steering Rack to 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

12. Clamp, Low Pressure Hose

13. Pipe, Fluid Cooler to Reservoir

14. Screw, Low Pressure Pipe

15. Reservoir, Fluid

16. Clamp, Low Pressure Hose

17. Bolt, Pipe to Sump Bracket

Figure 9-196

Legend

1. Screw, Hose Bracket

2. Hose, Fluid Cooler to Gear

3. Cooler, Fluid

4. Clamp, Hose (4 places)

5. Hose, Fluid Cooler to Reservoir

6. Pipe, Power Steering Rack

7. Pipe, To Fluid Reservoir

8. Screw, Cooler Bracket

9. Screw, Fluid Cooler (2 places)

3.18 LEFT-HAND DRIVE POWER STEERING FLUID COOLER AND

HOSE/PIPE ROUTING - GEN III V8 ENGINE

LT Section No. – 06-400

ARRANGEMENT

Refer to Figures 9-197 and 9-198 for the general arrangement of the power steering fluid 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.

Figure 9-197

Legend

1. Assembly, Steering Rack

2. O-ring, Fluid Pipe to Gear

3. Flare Nut, Fluid Pipe (2 places)

4. Pipe, Steering Gear to Cooler

5. Pipe, Steering Gear to Pump

6. Clamp, Low Pressure Hose

7. Hose, Low Pressure to Reservoir

8. O-ring, Fluid Pipe to Pump

9. Flare Nut, Fluid Pipe

10. Hose, Low Pressure to Reservoir

11. Screw, Low Pressure Pipe

12. Clamp, Low Pressure Hose

13. Pipe, Fluid Cooler to Reservoir

14. Bolt, Pipe to Sump Bracket

15. Reservoir, Fluid

16. Clamp, Low Pressure Hose

17. Bolt, Pipeto Sump Bracket

Figure 9-198

Legend

1. Pipe, Cooler to Steering Gear

2. Hose, Cooler to Steering Gear

3. Hose, Cooler to Reservoir

4. Clamp, Hose (4 places)

5. Pipe, Steering Gear

6. Screw, Cooler Bracket

7. Pipe, Fluid Reservoir

8. Cooler, Steering Fluid

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. Power steering 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 power steer ing fluid level in the reservoir is f ound to be low, refill and c heck the entire hydraulic

system for power steering 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 power steering fluid level.

2. Air in the power steering 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 power steering fluid level.

2. Drive belt slipping.

3. High internal leakage.

Steering Wheel Surges or Jerks when Turning with Engine Running, Especially During Pa rking.

1. Low power steering 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 power steering 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.

Further possible causes could be:

1. Sticky flow control valve.

2. Insufficient pump pressure output.

3. Excessive internal pump leakage.

4. Excessive internal system leakage.

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

1. Air in the power steering fluid, and loss of power steering 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 power steering fluid.

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

5. Verify exact point of leakage.

Example: T he location that the power steer ing fluid drips f rom is not necessar ily the leakage point - power steer ing

fluid could be overflowing from the reservoir 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 power steering fluid level in the pump’s reservoir. Add power steering 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 c leaning the sealing surf aces. Replace the shaf t only if very severe pitting is found. 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 9-199.

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 9-199

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............... 2.7

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

POWER STEERING PUMP

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

Type

V6..................................................................... 'N' Series vane type

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

Pressure at 1,000 engine rpm

V6..................................................................... 7,580 - 8,270 kPa

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

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

Lubrication (Power Steering)

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

Power Steering Fluid Capacity........................... Approx. 650 ml

Note: Use power steering fluid level indicator as a

final check to ensure correct refill quantity

Drive Belt Tension

V6..................................................................... Belt Self Adjusting

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

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

SEALANTS

Specified Locations............................................ Loctite 242 or equivalent

RTV T32 Silicone Sealant

6. TORQUE WRENCH SPECIFICATIONS

STEERING COLUMN ASSEMBLY

Steering Wheel Retaining Bolt................................................ 40 - 50

Upper Steering Column Mount Attaching NUt........................ 15 - 30

Lower Steering Coupling to Steering Gear Pinion Clamp Nut 23 - 30

Steering Shaft Lower Bearing Support Retaining Nuts........... 15 - 30

♦ Steering Coupling to Gear Pinion Cam Bolt Nut..................... 23 - 30

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 Gear Housing to Crossmember Mounting Nut......... 60, then 40° - 50° turn angle

Steering Gear Feed Pipe Flare Nut......................................... 15 - 25

Tie Rod Socket Adjustment Lock Nut..................................... 50 - 85

Valve Housing to Gear Housing Attaching Screws................. 5 - 6

Tie Rod Socket Stud Castellated Nut ..................................... 50 - 85

§ Tie Rod to Rack and Piston Assembly.................................... 90 - 100

V6 POWER STEERING PUMP

Reservoir Attaching Screw...................................................... 3.0 - 7.0

Pump Pulley Attaching Bolt..................................................... 20 - 30

Pump to Retaining Bracket Bolt.............................................. 30 - 40

Power Steering Pump Outlet Fitting........................................ 50 - 102

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 Cylinder Head Bolt................................. 20 - 35

Reservoir BGearet Mounting Bolts.......................................... 50

Fasteners must be replaced after loosening.

• Vehicle mus t be at kerb height before final tightening.

♦ Fasteners have micro encapsulated sealant applied and should be replaced after being loosened. If

in doubt, replacement is recommended.

7. SPECIAL TOOLS

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

211-258 TIE ROD WRENCH

Previously released.

Unique

211-259

LOWER PINION BEARING

REMOVER

Previously released.

Used in conjunction with Driver

Handle AU355-A.

Unique

7005 POWER STEERING PUMP

PULLEY INSTALLER

Previously released.

Desirable

7185 POWER STEERING PUMP

PULLEY REMOVER

Previously released.

Desirable

9A10

STEERING LINKAGE BALL STUD

REMOVER

Previously released.

Desirable

9A23 EXPANDER - SLEEVE SEALS

Previously released.

Unique

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

AU188 PRESS PLATES

Previously released.

Unique

AU211-A RACK PAD ADJUSTING SCREW

WRENCH

Previously released.

Desirable

AU301 RACK PAD ADJUSTING SCREW

LOCK NUT WRENCH

Previously released.

Desirable

AU306 LOWER PINION BEARING

REMOVER

Previously released.

Unique

AU307 LOWER PINION BEARING

INSTALLER

Previously released.

Unique

AU313 UPPER PINION POWER

STEERING FLUID SEAL

INSTALLER

Previously released.

Used to install valve housing

bearing.

Unique

AU314 VALVE HOUSING SEAL AND

BEARING REMOVER

Previously released.

Unique

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

AU315 VALVE HOUSING SEAL &

BEARING INSTALLER

Previously released.

Unique

AU316 PRE-LOAD ADAPTOR

Previously released.

Unique

AU355-A DRIVER HANDLE

Previously released as KM523-1.

Used in conjunction with AU306

and AU315.

Unique

AU392 PRESSURE HOSE SET

Previously released.

Comprises:

AU392-1, hose with male end

fitting.

AU392-2, hose with female end

fittin

Mandatory

AU440 CONTRACTOR - SLEEVE SEALS

Previously released.

Unique

AU456 RACK SEAL PROTECTOR - LONG

Previously released.

Unique

AU460 INSTALLER - INNER RACK SEAL

AND SPACER

Previously released.

Used in conjunction with Driver

Handle AU355-A.

Unique

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

AU527 INTERMEDIATE PINION

BEARING AND POWER

STEERING FLUID SEAL

INSTALLER

Previously released.

Used in conjunction with Driver

Handle AU355-

Unique

AU528 UPPER PINION BEARING AND

POWER STEERING FLUID SEAL

INSTALLER

Previously released.

Unique

E1408 STEERING WHEEL PULLER

LEGS

Previously released.

Desirable

E1460-1 POWER STEERING PUMP

SHAFT SEAL INSTALLER

Previously released as 9A61.

Unique

E1461-1 PRESSURE GAUGE ASSEMBLY

Previously released.

Mandatory

E6673

PRESS RLATES

Previously released as J22912-1

Desirable

E7115 ANGLE WRENCH

Previously released.

Desirable

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

E8803-6 RACK SEAL PROTECTOR -

SHORT

Previously released.

Unique

E8803-7 RACK PISTON TOOL

Previously released.

Used to rotate the end bushing to

remove/install retaining wire clip.

Unique

E8803-9 RACK PISTON SEAL EXPANDER

Previously released.

Used to expand the rack piston seal

prior to installation.

Unique

E8803-10 RACK SEAL TEST ADAPTOR

Previously released.

Used in conjunction with hand

vacuum pump to assess rack seal

serviceability.

Mandatory

E8803-11 RACK END SEAL/BUSH

INSTALLER

Previously released.

Used to install rack end seal and

bush.

Unique

E9239 POWER STEERING PUMP

PULLEY INSTALLER

Previously released as J25033-B.

Desirable

ETX30H TOR X BIT

Previously released.

Also commercially available as a

T30H Torx bit

Mandatory

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

J1859-A STEERING WHEEL PULLER

Previously released.

Unique

J23738-A HAND VACUUM PUMP

Previously released or use

commercially available equivalent.

Mandatory

J25359-8 TORX BIT HOLDER

Previously released or

commercially available.

Used with ETX30H Torx bit.

Mandatory

J25765-A DIAL TYPE TORQUE WRENCH

Previously released or use

commercially available equivalent,

capable of measuring from 0.4 - 6.0

Nm.

Mandatory