power steering fluid NISSAN PULSAR 1987 Workshop Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 3 of 238
CONTENTS
INTRODUCTION........................................ 5
VEHICLE IDENTIFICATION AND
GENERAL SPECIFICATIONS................. 7
GENERAL INFORMATION...................... 8
Tools and equipment ............................................. 8 Safety .................................................................... 10
General repair procedures..................................... 11
LUBRICATION AND MAINTENANCE... 14
Specifications......................................................... 14
How to grease and oil change .............................. 14
Service schedule ................................................... 17
WHEELS AND TYRES............................. 21
Specifications......................................................... 21
How to change a road wheel ................................ 21
Tire wear troubl e shooting ..................................... 22
Care and main tenance ......................................... 23
ENGINE TUNE-UP.................................... 25
Tune-up specifications ........................................... 25
Tune-up operat ions............................................... 25
ROADSIDE TROUBLE SHOOTING....... 32
Trouble shoot ing.................................................... 32
To check ignition and el ectrical system ................ 33
To check fuel system ............................................ 34
To check mechani cal system ................................ 35
ENGINE....................................................... 37
Specifications ........................................................ 37
Engine mechanical tr ouble shooting ...................... 39
Description ............................................................ 41
Engine and transaxle assembly ........................... 42
Manifolds ............................................................... 44 Camshaft, rocker arms and tappets..................... 48
Cylinder head........................................................ 50
Engine sump and oil pum p pickup pipe................ 54
Oil pump ............................................................... 55
Pistons, connecting rods and cylinder bores ........ 57
Crankshaft and bearings ...................................... 60
Flywheel /drive plate............................................... 63
Engine mountings.................................................. 64
Exhaust system .................................................... 66
COOLING AND HEATING SYSTEMS.... 68
Specifications ........................................................ 68 Cooling system trouble shooting ........................... 68
Heater and air conditioner trouble shooting ......... 69 Description ............................................................ 70
Radiator ................................................................ 70
Cooling fan ............................................................ 73
Thermost at............................................................ 75
Thermostat housing .............................................. 76
Water pump .......................................................... 76
Welch plugs .......................................................... 76
Heater unit, water valv e and controls ................... 77
Blower fan ............................................................. 80
Air condition ing ..................................................... 80
FUEL AND ENGINE MANAGEMENT ... 82
Specifications ........................................................ 82 Fuel and engine management trouble shooting ... 82
Description ............................................................ 84
Service precautions and procedures
..................... 86
System diagnosis and adjustments ...................... 89
Fuel supply components ....................................... 92
Air flow components .............................................. 98
Electronic components .......................................... 104
EMISSION CONTROL............................. 117
Introduction ........................................................... 117
Crankcase ventilati on system............................... 117
Evaporate control system..................................... 117
Air preheat system — 1.6 liter engines ................ 119
Exhaust control system ........................................ 120
CLUTCH...................................................... 121
Specifications........................................................ 121
Clutch trouble shooting......................................... 121
Description ............................................................ 122
Clutch unit and release mechanism..................... 123
Clutch pedal ......................................................... 124
Clutch c able.......................................................... 124
Clutch adjustments ............................................... 125
MANUAL TRANSAXLE AND
DRIVE SHAFTS......................................... 126
Specifications ........................................................ 126
Manual transaxle and drive shaft trouble shooting 126
Description............................................................ 128
Transaxle assembly.............................................. 129
Differential and final drive assembly ..................... 135
Gear lever assembly ............................................ 136
Drive shafts .......................................................... 137
AUTOMATIC TRANSAXLE....................... 140
Specifications........................................................ 140
Automatic transaxle trouble shooting.................... 140
Description............................................................ 141
Transaxle fluid ...................................................... 141
Brake band........................................................... 142
Kickdown cable .................................................... 142
Transaxle select or linkage ................................... 142
Neutral safety switch ............................................ 142
Transaxle assembly .............................................. 143
STEERING................................................. 145
PART 1. STEERING TROUBLE SHOOTING....145
Faults, causes and remedies................................ 145
PART 2. MANUA L STEERING......................... 147
Specifications ........................................................ 147
Description............................................................ 147
Steering wheel ...................................................... 147
Steering column.................................................... 148
Steering gear assembly ....................................... 149
PART 3. POWE R STEERING .......................... 152
Specifications........................................................ 152
Description............................................................ 152
In car adjustments, checks and minor repairs ..... 152
Steering wheel ...................................................... 153
Steering column.................................................... 153 Power steering pump ........................................... 153
Power steering gear assembly............................. 154
Page 10 of 238
10 General Information
If tools are to be stored for any length of time, it is
good policy to wipe them with an oily cloth.
Bladed screwdrivers should be checked for dam-
age to the tip. If necessary, the tip can be returned to
its original profile by careful grinding. Do not grind
screwdriver tips to a sharp point.
Hammer heads should be secure on their handles
and should be regularly checked for cracking or other
damage.
Chisels and punches should be checked for dam-
age or 'mushrooming' of the head. Any faults should
be rectified by grinding.
Hydraulic jacks should be regularly checked for
fluid leaks. Chassis stands and car ramps should be
checked for damage and cracks. Any equipment that
is suspect should not be used.
STORES
For routine maintenance, stores of automotive
oils, greases and additives should be kept on hand.
The following is a suggested list.
Engine oil.
Brake fluid.
Manual transmission or automatic transmission
oil — automatic transmission oil is also used in
the power steering system.
Rear axle oil.
Cooling system corrosion inhibitor/antifreeze.
Chassis grease.
High melting point grease, for hub bearings etc.
Penetrating oil or spray.
Kerosene or similar cleaning solvent.
Methylated spirits.
Oils and greases are available in handy pack size for
do-it-yourself lube jobs.
2. SAFETY
PERSONAL SAFETY
Safety when working on a motor vehicle is basical-
ly a matter of commonsense. Some safety precautions
to prevent personal in juries are as follows.
Raising a Vehicle
Always jack a vehicle on firm, level ground and at
the specified jacking points . Ensure that the wheels
remaining on the ground are fully chocked.
After raising the vehicle, place chassis stands
underneath and allow the weight of the vehicle to rest
on them. Do not use bricks, blocks of wood or similar
material.
NOTE: Never work under a vehicle which is
only supported by a jack.
Electrical System
Always disconnect the negative battery terminal
when working on any electrical components. Avoid
wearing metal watches, rings and chains which may
short across live terminals.
As battery gases are explosive, keep naked flames
and sparks clear of the work area. When connecting
and disconnecting jumper leads, use extreme caution
to avoid sparking.
Electronic Ignition Systems
Electronic ignition systems produce dangerous
high tension voltages in bo th the primary and second-
ary circuits which can be fatal. Exercise extreme
caution when working on or near any ignition system
components. Do not disconnect high tension leads
while the engine is running.
Work Area
Do not run the engine in a confined space. Ensure
that the work area is adequately ventilated.
Spilt oil or water should be cleaned immediately
to avoid the possibility of slipping.
Fuel System
Always disconnect the negative battery terminal
when working on any fuel components. Do not smoke.
Keep naked flames and sparks clear of the work area.
Do not siphon fuel using the mouth. Use a hand
pump or suitable siphon.
Do not attempt to repair a fuel tank by welding it.
This is an extremely hazardous procedure and should
be entrusted to a specialist.
Cooling System
To avoid scalding, use caution when releasing the
radiator cap on an engine wh ich is at normal operating
temperature. Turn the cap anti-clockwise to the first
stop and allow any pressure in the system to release.
When the pressure is released, remove the cap from
the radiator.
Brakes
As asbestos is used in some brake lining material,
avoid inhaling brake dust. Do not use compressed air
to remove the dust. Gentle brushing with a small
brush or using a vacuum cleaner with a hose attach-
ment are the safest methods of cleaning the brakes.
The above precautions also apply to the clutch plate
lining material.
Page 14 of 238
14
LUBRICATION AND MAINTENANCE
SPECIFICATIONS
CAPACITY AND GRADE
Engine:
Lubricant........................................... 15W-50 SF
Sump capacity including filter ........... 3.3 liters
Cooling system capacity............................ 6.0 liters
Manual transaxle:
Lubricant....................................... 80W-90 GL-4
Capacity ............................................... 2.7 liters
Automatic transaxle:
Lubricant.............................................. Dexron II
Capacity ............................................... 6.0 liters
Power steering:
Lubricant.............................................. Dexron II
Capacity ............................................... 1.0 liters
Manual steering lubricant ........ Castrol EPLl grease
Brake fluid type ................................................ Dot 4
1. HOW TO GREASE AND OIL CHANGE
(1) Run the front of the vehicle onto car ramps
and stop the engine. Chock the front wheels. (2) Raise the rear of the vehicle and place
chassis stands under the rear jacking points.
NOTE: It is best if the vehicle is kept as level
as possible to avoi d false readings when
checking the lubricant levels.
(3) Clean around the engine sump drain plug.
(4) Place a drain tin under the engine sump,
remove the engine sump drain plug and allow the
engine sump to completely drain.
NOTE: It is best to drain the engine sump
with the oil at operating temperature. How-
ever, if the oil is hot take care to avoid
scalding.
(5) Check that the sealing gasket on the sump
plug is in a serviceable condition. (6) When the engine sump has completely
drained, install and firmly tighten the sump drain plug.
Wipe around the plug after installation. (7) Place the drain tin under the oil filler,
remove the oil filter using a filter removal tool and
allow the residual engine oil to drain. Smear the
scaling ring of the new filter with engine oil and
lighten the filter by hand as per the instructions
supplied with the new filter.
NOTE: Before installing the new filter, en-
sure that the sealing gasket from the old
filter has not adhered to the filter sealing
surface on the engine.
(8) Remove the level checking plug from the
Location of the engine sump drain plug.
Removing the engine oil filter using a filter removal tool.
Page 42 of 238
42 Engine
The cylinder block is a cast iron alloy, deep skirt
design and the crankshaft is supported in the cylinder
block by five precision insert replaceable main bear-
ings. Crankshaft end float is controlled by the flanged
centre main bearing. Connecting rods are I section
forgings equipped with precision insert replaceable big
end bearings. The gudgeon pins are an interference fit
in the connecting rod and a floating fit in the piston.
The cast aluminum pistons are equipped with
two compression rings and one oil control ring.
The twin rotor, involute gear oil pump is mounted
directly to the front face of the cylinder block. The
inner rotor is internally driven by the crankshaft. The
oil pump pressure relief valve is not adjustable, and
consists of a plunger and spring mounted in the oil
pump body.
The pump draws oil through a screen in the sump
and delivers it, via a full flow replaceable oil filter, to
the oil gallery from where it is distributed to the
hydraulic tappets, camshaft and crankshaft bearings
and to the overhead rocker and valve mechanism.
3. ENGINE AND TRANSAXLE ASSEMBLY
Special Equipment Required:
To Remove and Instill — Suitable lifting tackle,
extra long chassis stands, suitable trolley
TO REMOVE
NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to
depressurize the system before removing any
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.
(1) Disconnect the negative battery terminal.
(2) Mark around the bonnet hinges with a soft
lead pencil Co facilitate correct installation. With the
aid of an assistant, remove the bonnet retaining bolts
and remove the bonnet from the vehicle.
(3) Drain the engine and transaxle lubricant.
(4) Open the coolant drain tap located on the
lower radiator pipe and drain the coolant. (5) Loosen the hose clips and disconnect the
heater hoses from the heater pipes at the bulkhead.
NOTE: Do not use excessive force to remove
the heater hoses from the heater pipes or the
heater core will become dislodged from the
heater unit. If necessary, cut the heater
hoses from the pipes using a sharp knife.
(6) Loosen the hose clamps and disconnect the
radiator hoses from the engine assembly. (7) Disconnect the positive lead from the bat-
tery. (8) On 1.8 liter models, disconnect the air inlet
duct.
(9) On 1.6 liter models, remove the air cleaner
assembly. Refer to the Fuel and Engine Management
section if necessary. (10) Disconnect the throttle cable from the throt-
tle body and from the camshaft housing top cover
bracket, if applicable. (11) Disconnect the fuel supply and return hoses.
Mark the hoses as an aid to installation. (12) Suitably mark and disconnect the charcoal
canister hoses. (13) Disconnect the injector wires from the injec-
tors. On 1.6 liter models, slide the wiring out from the
throttle body. (14) Disconnect the wiring fr om the throttle po-
sition sensor (TPS), idle air control (IAC) valve,
oxygen (O
2) sensor wire, coolant temperature sensor,
coolant sender and on 1.8 liter models, the manifold
air temperature (MAT) sensor. (15) Disconnect the wiring connector adjacent to
the top heater hose, the wiring from the alternator and
the two earth wires from underneath the cylinder head
bolts. (16) Lay the wiring loom over on the passenger
side of the engine compar tment, clear of the work
area.
(17) On manual transaxle models, loosen the
clutch cable adjusting nuts and remove the cable
through the slot in the lever. Remove the clutch cable
bracket from the transaxle after removing the retain-
ing bolts and place the cable to one side.
(18) Disconnect the wiring from the starter mo-
tor, speedometer sender and on manual transaxle
models, the reverse lamp switch wiring.
(19) If applicable, disconnect the power steering
lines from the pump and drain the fluid into a
container. Suitably plug the lines and the pump to
prevent the entry of dirt.
(20) On automatic transaxle models, disconnect
the selector cable and bracket from the transaxle
assembly.
Disconnect the transaxle oil cooler lines from the
transaxle. Plug the lines and fittings to prevent the
entry of dirt etc.
(21) Loosen the front wheel nuts, raise the front
of the vehicle and support it on extra long chassis
stands. Ensure that the vehicle is high enough to allow
removal of the engine from underneath. (22) Remove the front wheels and the engine
splash guards from the vehicle.
(23) On manual transaxle models, remove the
stay rod and control rod bolts and nuts and disconnect
the rods from the transaxle.
(24) Remove the lower control arm to steering
knuckle ball joint nuts and separate the ball joints
from the steering knuckle by holding a dolly or a
hammer against one side of the steering knuckle and
hitting the other side with a hammer. The taper on the
ball joint will release fr om the steering knuckle.
(25) Pull the steering knuckles outward swiftly to
Page 44 of 238
44 Engine
Rear three quarter view of the 1.8 liter engine and automatic transaxle assembly.
mountings. Lower the assembly onto the mountings
and tighten the mounting nuts and bolts.
(4) Install a new exhaust flange gasket.
(5) Fill the engine and transaxle with the correct
quantity and grade of lubricant. (6) Fill the cooling system as described in the
Cooling and Heating Systems section. (7) On models with power steering, fill the power
steering reservoir with the recommended fluid.
(8) Start and run the engine until it reaches the
normal operating temperatur e and check for fuel, oil
and coolant leaks.
4. MANIFOLDS
INLET MANIFOLD - 1.6 Liter Models
To Remove and Install
NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to
depressurise the system before removing the
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.
(1) Disconnect the negative battery terminal.
(2) Remove the wingnuts retaining the air
cleaner to the throttle body, lift the air cleaner
upwards slightly and disconnect the vacuum hoses. (3) Drain the cooling system as described in the
Cooling and Heating Systems section. (4) Loosen the hose clamps and disconnect the
engine coolant hoses from the rear of the manifold.
(5) Disconnect the small branch of the engine
ventilation hose from the rear of the inlet manifold. (6) On automatic transaxle models, disconnect
the kickdown cable from the throttle lever by releasing
the wire spring clip and re moving the cable end socket
from the ball.
(7) Turn the throttle lever to the full throttle
position. Using the slack in the throttle cable, release
the throttle cable end thr ough the slot provided.
Page 145 of 238
145
STEERING
PART 1. STEERING TROUBLE SHOOTING
FAULTS, CAUSES AND REMEDIES
EXCESSIVE PLAY OR LOOSENESS IN
STEERING GEAR
(1) Tie rod end ball joint loose or worn: Tighten
or renew the worn tie rod end ball joint. (2) Steering gear assembly loose on cross-
member: Inspect for damage and tighten the steering
gear mounting bolts. (3) Steering gear worn: Overhaul the steering
gear.
(2) Low fluid level in the power steering reser-
voir: Check for leakage, repa ir and/or renew the faulty
components. Top up the fluid level.
(3) Suspension worn or out of alignment: Check
the front suspension for wear, renew the worn com-
ponents and realign. (4) Misalignment between the steering gear and
column mountings: Check and align the steering gear
and column mountings. (5) Binding in the steering shaft universal coup-
ling joints: Check the join ts and renew if necessary.
(6) Ingress of dirt into the steering gear due to a
defective boot: Clean, check and lubricate the internal
components of the steering gear and renew the
defective boot. (7) Insufficient power steering pump pressure:
Check the pump drive belt tension and reservoir fluid
level. If necessary renew the pump assembly.
NOTE: Ensure that both front tires have
ample depth of tread and are inflated to the
correct pressure. Check the front suspension
components for wear before having the steer-
ing geometry checked. See the Front Sus-
pension section for the component checking
procedures.
Check the tie rod ends for wear and the rubber boots for deterioration.
(4) Worn front hub bearings: Check the condi-
tion and renew the front hub bearings. (5) Worn or damaged front suspension control
arm bushes: Renew the control arm or bushes.
NOTE: Looseness in th e steering linkage is
best assessed with the weight of the vehicle
on the front wheels. Have an assistant turn
the steering wheel from left to right while the
inspection for wear is being made. If loose-
ness is found to be in the steering gear, it
will be necessary to overhaul the steering
gear assembly.
HEAVY STEERING
(1) Low or uneven tir e pressures: Check the
tires and inflate to the recommended pressures.
Checking the steering rack boot s for splits and deteri-
oration.
Page 146 of 238
146 Steering — Part 1
STEERING PULLS TO ONE SIDE
(1) Uneven tire wear or pressures: Check the
condition of the tires and inflate to the recommended
pressures.
(2) Incorrect front wheel alignment: Check and
align the front end.
(3) Dragging brakes: Check each wheel for drag-
ging brakes. Overhaul the brakes as necessary. (4) Damaged suspension or crossmember: In-
spect and renew the damaged components. (5) Faulty power steering gear assembly: Re-
move the power steering gear for overhaul.
FRONT WHEEL WOBBLE OR SHIMMY
(1) Uneven tire wear or incorrect tire pressures;
Check the condition of the tires and inflate to the
recommended pressures. (2) Tire or wheel imbalance: Check and balance
as necessary (3) Worn or badly adjusted hub bearings: Check
the condition and adjust the front hub bearings.
(4) Faulty or worn suspension, units: Check and
overhaul or renew as a pair.
NOTE: Check the steering linkage as previ-
ously described. Raise the front of the vehi-
cle and check the adjustment of the hub
bearings by moving the road wheel in and
out at the top and bottom. No movement in
the bearings should be felt. Check the sus-
pension units as outlined in the Front Sus-
pension section.
STEERING ERRATIC OR WANDERING
(1) Incorrect or uneven wheel alignment setting:
Check and adjust th e steering geometry.
(2) Smooth front tires: Check and renew the
tires as necessary.
Checking the steering gear mounting bolts for security.
(3) Steering gear assembly loose on the cross-
member: Inspect for damage and tighten the steering
gear mounting bolts.
(4) Wear in the tie rod ball housing: Renew the
worn t i e rod and ball housing. (5) Wear in the rack and pinion: Remove the
steering gear assembly for overhaul. (6) Loose or incorrectly adjusted hub bearings:
Check and adjust the front hub bearings.
FAILURE OF POWER ASSISTANCE
(1) Loose or broken pump drive belt: Renew or
adjust the pump drive belt.
(2) Low fluid level in the power steering reser-
voir: Check for leakage, repair or renew the faulty
components. Top up the fluid level. (3) Insufficient power steering pump pressure:
Check the delivery pressure, renew the pump if
defective. (4) Faulty power steering gear assembly: Re-
move the power steering gear assembly for overhaul.
Page 152 of 238
152
PART 3. POWER STEERING
SPECIFICATIONS
Steering gear type ................Rack and pinion with
integral power cylinder
Steering column type .................... Energy absorbing
collapsible and lilt adjustable
Steering wheel free play ................................. 35 mm
Number of turns lock to lock:
TRW ...............................................................2.82
PR24SA ........................................................... 2.7
Linkage.....................................Direct from rack ends
to ti e rods and steering knuckles
Power steering pump
maximum pr essure.................................... 6 865 kPa
Lubricant ...................................................... Dexron II
TORQUE WRENCH SETTINGS
Steering gear to bulkhead mounting bolts... 108 Nm
Tie rod to steering knuckle nut ...................... 98 Nm
Tie rod to tie rod end locknut....................... 98 Nm
Tie rod ball housing to rack............................ 88 Nm
Power steering pump pulley nut ..................... 68 Nm
1. DESCRIPTION
The vehicles covered by this manual are equipped
with either a TRW power steering system or a
Japanese PR24SA power steering system.
Both types are similar in construction and appear-
ance.
The power steering is a rack and pinion type
which is mounted on the lower section of the engine
compartment bulkhead by rubber mountings and
brackets.
Hydraulic pressure is supplied to the power
steering gear by a pump driven by a drive belt from
the engine.
The power steering pump has a separate fluid
reservoir located on the righ t side of the bulkhead.
No lubrication of the steering gear or steering
pump is required in service and in the event of the
loss of power assistance, the steering will continue to
operate but will require a greatly increased effort.
However, as the steering gear and pump are lubricated
by the power steering fluid, the cause of the loss of
power steering or fluid loss must be determined and
repaired promptly to prevent damage to the steering
pump and to a lesser extent, the steering gear.
The t i e rod ends and rubb er boots can be renewed
without removing the steering gear from the vehicle.
To renew the integral t i e rod and tie rod ball housings,
the steering gear must be removed.
As specialist knowledge and equipment are re-
quired to overhaul the power steering gear and the
hydraulic pump, it is recommended that these op-
erations be carried out by an authorized dealer.
However, procedures for the removal and installa-
tion of the steering gear and pump are fully de-
scribed in this section.
The steering column is of the energy absorbing
type and is designed to collapse in the event of a
severe front end collision. The energy absorbing com-
ponents are the column tu bes, steering shaft and tilt
bracket breakaway capsules. All these components
should be handled with extr eme care if service opera-
tions are to be carried out on the steering column
assembly.
2. IN CAR ADJUSTMENTS, CHECKS AND
MINOR REPAIRS
If the power steering system becomes partially or
fully inoperative it is most important that the follow-
ing preliminary inspection and testing procedure be
performed prior to undertaking any trouble shooting
or repair operations.
PUMP DRIVE BELT
Inspect the pump drive belt for breakage, glazing
or wear. If any of these characteristics are evident,
renew the belt using only a genuine replacement.
If the belt is loose but still serviceable, adjust it
using the procedure outlined in the Engine Tune-up
section.
NOTE: In most cases a loose drive belt can
be heard squealing when a load is placed on
the pump as the steering wheel is turned or
as the engine speed is increased.
Checking the power steering pump drive belt for
deterioration.
Page 153 of 238
Steering — Part 3 153
TO CHECK FLUID LEVEL
Check the fluid level in the power steering reser-
voir when the fluid is cold.
If it is necessary to top up the fluid, fill to between
the arrow marks on the dipstick using the recom-
mended fluid.
NOTE: Do not overfill the reservoir.
Checking the power steering fluid level using the
dipstick incorporated in the cap.
TO CHECK FOR FLUID LEAKS
Using a suitable solvent, clean around all power
steering assemblies and hose fittings where fluid
leakage might occur and start the engine. Turn the
steering wheel from one steering lock to the other
several times and stop the engine. Check for leakage.
Where leakage is found at ho se fittings, tighten and
recheck.
If the leak remains, renew the hoses or fittings as
required.
Where leakage is found in the steering gear
assembly or pump assembly, specialist attention is
necessary.
TO CHECK STEERING WHEEL FREE PLAY
With the engine running and the steering wheel in
the straight ahead positi on, measure the free move-
ment of the steering wheel before the front wheels
move. This is specified as steering wheel free play and
if it exceeds Specifications, check for free play in the
steering linkages and the universal coupling joints. If
these components are satisfactory, it will be necessary
to remove the steering gear from the vehicle for
renewal or overhaul.
PUMP BELT TENSION
The procedure for adjusting the power steering
pump bell tension is describe d in the Engine Tune-up
section
TO PURGE THE POWER STEERING SYSTEM
OF AIR
(1) Check that the pump reservoir is filled to the
correct mark on the dipstick. (2) Raise the front of the vehicle and support it
on chassis stands. (3) Turn the steering wheel quickly from lock to
lock several times, recheck the fluid level within the
pump reservoir and top up if required. (4) Start the engine, allow it to idle and slowly
turn the steering wheel from lock to lock several times.
Do not hold the steering at full lock for more than 15
seconds. (5) Check the fluid level in the pump reservoir,
top up if necessary. (6) If the fluid is aerated within the pump
reservoir or if pump noise persists, repeat operations
(3) to (6).
3. STEERING WHEEL
The procedure for removing and installing the
steering wheel is fully covered in the Manual Steering
section under the above heading.
4. STEERING COLUMN
The procedure for removing, dismantling and
assembling the steering column is fully covered in the
Manual Steering section under the above heading.
5. POWER STEERING PUMP
TO REMOVE AND INSTAL
( 1 ) Disconnect the negative battery terminal.
View of the power steering pump removed from the
vehicle.
Page 154 of 238
154 Steering —
(2) Remove the air inlet duct from the air
cleaner and throttle body. (3) Position a container or a piece of cloth
beneath the steering pump reservoir and disconnect
the fluid return and power steering pump supply hose
from the reservoir.
(4) Loosen the steering pump drive belt as
described in the Engi ne Tune-up section.
(5) Loosen the return hose clamp and the supply
union and disconnect the hoses from the power
steering pump. Plug the hoses to prevent the loss of
fluid.
(6) Loosen the retaining bolts and withdraw the
pump. (7) Thoroughly clean the exterior of the steering
pump and inspect it for cracks, damage and signs of
leakage.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Install the pump and retaining bolts.
(2) Install the drive belt and adjust it as de-
scribed in the Engine Tune-up section. (3) Install the hoses to the power steering pump
and tighten securely. (4) Top up the pump reservoir and purge the
power steering system of air as previously described.
TO OVERHAUL
As specialist knowledge and equipment arc re-
quired to overhaul the power steering pump, it is
recommended that this operation be performed by an
authorized dealer or steering specialist.
6. POWER STEERING GEAR ASSEMBLY
Special Equipment Required:
To Renew Tie Rod Ball Housings — Large Still-
sons
TO REMOVE AND INSTAL
The procedures for removing and installing the
power steering gear are similar to those carried out in
the Manual Steering section under the Steering Gear
Assembly heading except fo r the following differences.
(1) Place a container under the pressure and
return pipes that are conn ected to the steering gear
valve housing. Remove the pipes and allow the fluid
to drain into the container. (2) Suitably seal the pipes and the steering gear
to prevent the entry of di rt whilst the pipes are
removed.
(3) Upon removal of the power steering gear,
thoroughly clean the steering gear except the tie rod
ends in a suitable solvent. Be careful not to allow the
solvent to enter the apertu res where the pressure and
return pipes were removed. (4) Check the pipes and co nnections for cracks,
damage or obstructions and renew as necessary.
Installed view of the power steering gear with the
engine removed.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Install the pressure and return pipes to the
steering gear valve housing and tighten securely. (2) Fill the power steering reservoir to the cor-
rect level and bleed the system as described previously
under the heading In Car Adjustments. Checks and
Minor Repairs. (3) Check all power steering pipe connections
for leaks and repair as necessary. (4) Check, and if necessary, adjust the front
wheel toe in as described in the Front Suspension
section. After adjustment ensure that the rubber boots
are not distorted or twisted and the rubber boot
clamps and clips are facing downward.
TO OVERHAUL
As specialist knowledge and equipment are re-
quired to overhaul the power steering gear, it is rec-
ommended that this opera tion be performed by an
authorized dealer or steering specialist.
TO RENEW TIE ROD BALL HOUSINGS
TRW Steering Gear
The renewal of the tie rod ball housings is the
same as for the manual steering gear. Refer to Part 2.
Manual Steering section.
PR24SA Steering Gear
(1) Remove the power steering gear assembly
from the vehicle as previously described.
(2) Carefully mount the power steering gear in a
vice equipped with soft jaws. Loosen the tie rod end
locknuts without disturbing the location of the tie rod
ends and unscrew the tie rod ends, taking note of the
number of turns required to remove them. Unscrew
and remove the locknuts from the tie rod. (3) Remove the clamps from the rubber boots
and remove the boots.