PONTIAC FIERO 1988 Service Repair Manual

3B7-8 POWER STEERING I
I
OUTLET PlPE
OUTLET PlPE
VlEW A
OUTLET PlPE HOSE
MUST BE INSTALLED TO CLEAR OUTLET PlPE
AND ALL SURROUNDING PARTS. MIN CLEARANCE
12.7 (HOSE MUST NOT BE TWISTED DURING
INSTALLATION.) HOSE ENDS MUST BE KEPT
FREE OF
DIRT AND OTHER CONTAMINANTS. DO NOT BEND OR DISTORT PIPES TO FACILITATE
INSTALLATION.
@ FOR LEAK REPAIR UNSCREW NUT AND REPLACE
GASKET REINSTALL AND TIGHTEN NUT TO
SPECIFIED TORQUE DO NOT OVERTIGHTEN NUT
TO REPAIR LEAKS
VlEW B
Figure 387-8 PIS Pump Hose LB8 Engine

I - SWIFT. DRIVE 14 - RING, PUMP 2 - SEAL. DRIVE SHAFT 15 .- PLATE, PRESSURE 3 - SEAL "0 RING (HOUSING) 18 - SPRING, PRESSURE PLATE 4 - MOUSIMG ASSY., PUMP 17 - PLATE. END 5 - SPRING, FLOW CONTROL 18 - RING, END PLATE RETAINING 6 - 4ALVE ASSV.. CONTROL' 19 - SEAL "0" RING (HOUSING TO STUD)* 7 - SEAL "0 RING (MOUSING) 20 - RESERVOIR ASSY.. PUMP* 8 - SEAL "0" RlMQ (PRESSURE END
PLATE) 21 - CAP ASSY., RESERVOIR * s - PIN. DOWEL n - STUD OR BOLT* 10 - L'LATE. TMRUST 23 - SEAL "0 RING (FITTING ASSY.) 11 - AOTOR, PUMP 24 - FITTING ASSY., CONNECTOR I 12 - RING. SHAFT RETAINING 25 - MAGNET ' 13 - VANE, PUMP
Figure 387-1 0 Power Steering Pump Assembly

3B7-10 POWER STEERING
I. REMOVE AND INSTALL DRlVE SHAFT SEAL W l THOUT DISASSEMBL ING THE PUMP.
REMOVE It6TALL
I PROTECT DRlVE SHAFT I COAT DRIVE SHAFT SEAL WITH SHIM STOCK WITH HYDRAULIC PVMP 2 USE Ch 5EL TO CUT FLUID. REFER TO INSET FOR
SEAL AND REMOVE DRIVE SHAFT SEAL INSTALLATION
DRAUCIC WMP ASSEMBLY
TOOL J-7728
1
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j
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2. REMOVE AND INSTALL PUMP RESERVOIR ASSEMBLY I REMOVE INSTALL I I. DRAIN OIL FROM RESERVOIR I. USE ALL NEW SEALS AND LUBRICATE
ASSEMBLY BEFORE REMOVAL. WlTH
POWER STEERING FLUID BEFORE 2. REMOVE PARTS AS SHOWN. INSTALLAT
ION. 2. INSTALL PARTS AS SHOWN.
TORQUE TO SJ N m
FITTING ASSEMBLY
TORQUE TO 50 N m
UMP REYRVOIR ASSEMBLY *
O-RING SEALS * . NOT USED ON
HOUSING ASSEMBLY 125-N SERIES
1 1 I
REFER TO INSET FOR I. LLleRlCATE EN) PLATE AND I RETAINING RING. INSTALL
PARTS AS WOWN. REFER TO
INSET FOR POSITIONING
OF I
I RETAINING RING 1
- - - - - - - LOCATE RlNG GAP I REMOVE RETAINING RING AT POSITION WOWN I
POSITIONING OF RETAINING
ATE RETAINING RlNG
VALVE
ASSEWY
OW CONTROL SPRING
LWTI(X : BEFORE PROCEEDING. EXAMIN THIS
PART Of TM DRIVE WAFT. IF IT IS C CROCUS CLOTH BEFORE REMOVING. THIS WILL PREVENT DAMAGE TO TM WAFT WING WHICH MIGHT REWIRE RERACEMNT OF 1% ENTIRE HOUSING.
-- J RING.
4. REMOVE AND INSTALL ROTATING GROUP.
REMOVE INSTALL
1. USING A RUBBER MALLET. I. INSTALL PARTS AS SHOWN ON
TAP LIGHTLY ON DRIVE
DRIVE WAFT. INSTALL NEW
WAFT UNTIL
PRESSVRE RETAINING RING ON DRIVE
PLATE IS FREE. SHAFT AND INSTALL IN PW 2. REMOVE RETAINING RING HOUSING.
FROM DRlVE WAFT AM 2, REFER TO INSET FOR POSITIONING
DISCARD. REMOVE PARTS OF PUMP RING IN HOUSING.
AS SHOWN.
7 VANES r------I T PRESSURE PLATE '1 NOTICE: INSTALL WITH
ROUNDED EDGE OF VANES OVTWARD.
WAFT. ROTOR AN) TWST PLATE ASSEMBLY
PUIAP RING.
C
\- HOUSING ASSEMLY
TpW ROTOR
WAFT RETAINING
I RETAINING RlNG REMOVAL I
5. REMOVE AND INSTALL DRIVE SHAFT AND
O-RING SEALS.
I RLAOM INSTML
I. REMOVE PARTS 1. REFER TO TM INSET FOR DRlVE
AS WOWN WAFT SEAL INSTALLATION
USE ALL NW SEALS AND 1 LVBRlCATE SEALS WlTH POWER J-7728 STEERING FLUID BEFORE
INSTALLATION
! 2. INSTALL PARTS AS WOWN .
I
INSTALL DRIVE SHAFT
HOUSING ASSEMBLY
I LDRIVE WAFT SEAL
BENCH REPAIR
Figure 3B7-11 Power Steering Pump Overhaul

POWER STEERING 387.1 "1
GENEML DESCRIPTION
These Integral Power Steering Gears
have a control valve which directs oil
to either side of the rack piston. The
rack piston converts hydraulic power
into mechanical force. This force is
transmitted to the mating
pitman
shaft teeth, through the pitman shaft
to the steering linkage.
The model
800 incorporates a
recirculating ball system in which
steel balls act as a rolling thread
between a steering worm-shaft and
the rack-piston.
I., U.. Per1 *.a. I -HOUSING. STEERING GEAR 1 -RACE, THRUST BEAPING (WORM)
3 -BEARING ASSY. ROLLER THRUST IWORMI 4 -RACE. IHRUST BEARING (WOWMI 5 -WORM. SlEERlNG 6 -SEAL. "0" WING (STUB SHAFT) 7 - SHAFT. STUB 8 - SPOOL. VALVE
9 - SEAL. "0 RING ISPOOL) I0 -BODY. VALVE I I - RING. VALVE BODY 13) I2 -SEAL. "0" RlNG [VALVE BODY) 131 13 - RETAINER. BEARING (ADJUSIERI I4 - SPACER, THRUST BEARING
I5 -RACE UPPER THRUST BEARING ISMALLI 16.- BEARING. UPPER THRUST I7 - RACE UPPER THRUST BEARING ILARGEI IB - SEAL. "0" RlNG IADJUSTER)
Whenever a part wh~ch
forms a sealing surface for an "0"
ring is removed, the "0" rlng seal
should also be removed and
replaced with a new seal. When-
ever one of the
P~tman shaft or
stub shaft seals are removed all
adjacent seals should be removed
and replaced
w~th new seals.
Lubr~cate all new seals w~th
power steer~ng flu~d to ease assembly
I,, Ue Pet1 Were I9 PLUG ADJUSTER 10 BEARING NEEDLE ?I SEAL SIUb SHAFT ?I SEAL SlUB SHAFT DUST
23 RlNG RETAINING
24 NUT ADJUSTER PLUG LOCK
IS BEARING ASSY NEEDLE PITMAN SHAFT
16 SEAL PITMAN SHAFT ISINGLE LIP 17 WASHER SEAL BACK-UP [PlTMnN SHAFT! 18 -SEAL PITMAN SHAFT [DOUBLE LIP1 29 -WASHER SEAL BACK-UP \PITMAN SHAFT
30 -RING RETAINING iPlTMAN SHAFT SEAL
31 -WASHER PITMAN SHAFT LOCK
32 - NUT PITMAN SHAFT
33 NUT RACK PISTON
34 -BALL
35
GUIDE BALL RETURN 2 36 CLAMP BALL RETURN GUIDE
tar1 Yemr SCREW ASSY LOCKWA5HER L It PLUG RACK PISTON
SEAL 0 RlNG IRACK PISTONI RlNG RACK PISTON
SEAL 0 RING HOUSING END PLUG
PLUG HOUSING END
RlNG RETAINING HOUSING END PLUG
GEAR ASSY
PITMAN SHAFT SEAL ASSY GASKET
COVER ASSY HOUSING SIDE BOLT HEX HEAD SIDE COVER, 4 NUT LASH ADJUSTER
SPRING CHECK VALVE
POPPET CHECK VALVE
CONNECTOR INVERTED FLARE
CONNECTOR INVERTED FLARE
--- - I
Figure 387-12 Overhaul 8001808 Gear, Chart A

1 -HOUSING. STEERING GEAR 2 --RACE. THRUST BEAPING (WORM) 3 -BEARING ASSY . ROLLER THRUST (WORM) 4 -RACE. THRUST BEARING IWORMI 5 ~-WORM. STEERING 6 - SEAL. "0" RlNG lSTUB SHAFTI 7 SHAFT. STUB 8 - SPOOL. VALVE 9 SEAL. "0" RlNG ISPOOL) I0 - BODY. VALVE I I - RING. VALVE 80DY (3) 12 -SEAL. "0" RlNG (VALVE BODY) (31 I3 - RETAINER. BEARING (ADJUSTER)
I4 - SPACER. THRUST BEARING
IS - RACE. UPPER THRIJST BEARING (SMALL) I6 -BEARING. UPPER THRUST
Ti I7 - RACE. UPPER THRUST BEARING (LARGE)
5- I8 -- SEAL, "0" RlNG IADIUSTERI C
Krv Ue Pert Nemc I9 - PLUG. ADJUSTER 20 - BEARING. NEEDLE 21 -- SEAL. STUB SHAFT 21 - SEAL. STUB SHAFT DUST 23 - RING. RETAINING 24 - NUT. ADJUSTER PLUG LOCK 25 - BEARiNG ASSY . NEEDLE (PITMAN SHAFT) 26 - SEAL. PITMAN SHAFT (SINGLE LIP) 27 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
28-SEAL. PITMAN SHAFT (DOUBLE LIP) 29 - VtASHER. SEAL BACK-UP (PITMAN SHAFT) 30 -RING RETAINING (PITMAN SHAFT SEAL)
31 -WASHER. PITMAN SHAFT LOCK 32 -NUT. PITMAN SHAFT 33 - NUT RACK PISTON 34 - BALL 35 -GUIDE. BALL RETURN (21 36 -CLAMP BALL RETURN GUIDE
Key No Pan Nrme 37 SCREW ASSY LOCKWASHER 8 (21 38 PLUG RACK PISTON 39 SEAL 0 RING (RACK PISTON) 40 RlNG RACK PISTON 41 SEAL 0 RlNG (HOUSING END PLUG, 42 PLUG HOUSING END 43 RING RETAINING iHOULlNG END PLUG 44 GEAR ASSY PITMAN SHAFT
45 SEAL ASSY GASKET
46 COVER ASSY HOUSING SlDE 4/ BOLT HEX HEAD ISIDE COVER) 14 48 NUT LASh ADJUSTER 49 SPRING CHECK VALVE 50 POPPET CHECK VALVE 51 -CONNECTOR INVERTED FLARE 52 -CONNECTOR INVERTED FLARE 53 BOLT COUPLING PINCH 54 COUPLING STEERING SHAFT

SEALS IN CAR
1 Clean exposed end 1 Install parts as shown 1 Remove parts 1 Install parts as shown of p~tman shaft and Open end of retalnlng end of houslng after rlng to
be approx 25 mm removlng p~tman arm HOUSING ASSEMBLY (1 ~nch) from access hole
2 Remove
retacnlng Inspect for burrs
Reta~ntng rlng rlng pl~ers J-4245
3 Start englne and
turn wheels fully SEAL (SINGLE LIP)
to the left to
force seals and
SEAL (DOUBLE LIP)
4 Turn off
englne
5 Inspect houslng
PITMAN SHAFT
Inspect seal sur
250 Newton Meters 1185 Ft. Lbs.) OUSING ASSEMBLY
HOUSING END PLUG
0 RING SEAL
HOUSING END PLUG
INSTALL
1 Remove parts as shown 1 Install parts as shown 1 If p~tman shaft and 1 If removed ~nstall s~de cover are to be gasket seal
by
separated remove bend~ng tabs around
When ~nstalllng rack.
preload adjuster nut cover edges
care should be taken not
2 Rotate stub shaft to
2 Install parts to cut teflon seal rack
center gear then as shown
remove parts as shown
SIDE COVER BOLTS
GASKET SEAL
PITMAN SHAFT
Insert ball retalner J-21552 Hold 1001 tightly agalnst worm whlle turnlng stub shaft counter-clockw~se The rack-p~ston will be forced
shaft
to asslst in removal. retalner from the gear
seal
from s~de houslng together
cover
lf requ~red
POWER STEERING 387.13
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Figure 3B7-14 Overhaul 8001808 Gear, Chad C

387-14 POWER STEERING
5. REMOVE AND INSTALL ADJUSTER PLUG
ASSEMBLY
REMOVE INSTALL
1 Loosen lock nut 1 Install parts
Use punch agalnst as shown
edge of slots
1 2. Remove adjuster fi plug using spanner
wrench J-7624.
ADJUSTEfi PLIJG
LOCK NUT
,
When installing adjuster
plug care should be taken
not to cut seals.
1 6. DISASSEMBLE AND ASSEMBLE ADJUSTER
PLUG ASSEMBLY
DISASSEMBLE ASSEMBLE
1 D~sassemble arts 1 Assemble Darts
as shown as shown ' a
CRETAINING RING STUB SHAFT
DUST SEAL
*STUB SHAFT SEAL
NEEDLE BEARING
ADJUSTER PLUG
-\\\\\\ILL 0 RINGSEAL
UPPER THRUST BEARING
UPPER BEARING RACE (SMALL)
THRUST BEARING SPACER
1 - -------, BEARING RETAINER
RETAINER
* Use stub shaft seal protector J-29810 on stub shaft when
installing stub shaft seal
Screwc:
lver
I ''C> - Pry bear~ng retatner E- -- - -- -A at ra~sed area
Use
suttable slze arbor to
press bearlng In place
Bear~ng to be pressed 16 mm ($,n mch) Into adjuster w,th stamped
I D end up and from d~rect~on of
arrow
/
4--.---- .A
Install bear~ng
7. REMOVE AND INSTALL BEARiNG, WORM,
I AND VALVE ASSEMBLY I
I REMOVE INSTALL I 1. Grasp stub shaft and 1. Install parts as
remove valve and worm shown.
assembly as a
unlt. '
Separate the valve from the worm
Note how the pln In the wo f~ts the slot In the valve
THRUST BEARING
WORM ASSEMBLY
reassembling gear make
sure angle of thrust races are
as shown
I 8. DISASSEMBLE AND ASSEMBLE VALVE
DISASSEMBLE ASSEMBLE
1 D~sassemble parts 1 Assemble parts
as shown as shown
VALVE BODY
0 RIN
VALVE BODY
VALVE SPOO
RING (teflon) *
SPOOL TO BODY 0 RING * To ease assemblv, soak
I-
- - - -- - - - -- , teflon rings in warm water. _ A Loosen shaft cap I B Remove and ~nstall stub shaft
I I PUII cap out approx G mrn(1/sv) I
Lap l~ghtly on
wood block I k~ln on shaft and hole In I spool (Disengage to remove) --C- - ----------
I C Remove and ~nstall spool ! D Engage stub shaft I
Rotate wh~le removlng LI
~nstalltng 1
Lubr~cate spool and body I Notch must fully engage w~th power steer~ng flu~d I pln and cap must seat I aga~nst shoulder
I 1
Figure 387-1 5 Overhaul 1 8001808 Gear, Chart D

POWER STEERING 387-1 6
7 1 1 9. DISASSEMBLE AND ASSEMBLE RACK
1 PISTON
I DISASSEMBLE ASSEMBLE
1 Disassemble parts 1 Assemble parts
as shown as shown
2 Clean and Inspect all parts for excessive wear The black balls are smaller than
the silver balls. The black and
silver balls must
be installed
alternately into the rack-piston
and return guide to maintain
rack piston to worm gear
praloed.
TEFLON SEAL AN0 0 RING--
If replaced lubricate new seal
and 0 rlng wlth power steerlng fluid
Turn worm until worm groove IS al~gned w~th the lower
I \ WORM-Slide all the way
I \
Into the ra~k-~lston
1
v Lubr~cate balls wlth
I / oower steerlno fluid install balls th;ough Before assembling rack
ball return gulde hole In houslng. ball retalner whlle rotatlng worm J-21552 must be lnserted counterclockw~se Into rack to allow
removal of worm
- GUIDE-Alternately ~nstall rema~nder of
balls and retaln w~th grease at each
end of gu~de
to 5 Newton Metres (4 Ft Lbs )
10. REMOVE AND INSTALL PITMAN SHAR
SEALS AND BEARING
REMOVE INSTALL
1 Clean end of 1 Coat seal Ilp and washer face houslng thoroughly with anhydrous calclum grease
to prevent dlrt from enterlng and be 2. Install parts as shown
extremelv careful not
to score
(he houslng
bore HOUSING ASSEMBLY
Inspect for burrs
2 Remove retalnlng rlng wlth snap rlng pllers J-4245
3 Uslng screw drlver. pry seals and washers
from bore
PITMAN SHAFT SEAL
(SINGLE LIP)
PITMAN SHAFT SEAL
(DOUBLE LIP)
RETAINING
RING 2
SEAL BACK UP WASHER NEEDLE BEARING
Remove onlv 11 ~t I - - - - - .- - - - . - . - . -. . - - 1 needs replacing.
I
When tool bottoms on
fully Installed
I I
L ------------ J L ----------- J
Install Pltman shaft bearlng Install Pttman shaft seals
CI I J
Figure 387-16 Overhaul 800f808 Gear, Chart E

387-16 POWER STEERING
11. REMOVE AND INSTALL CHECK VALVE
REMOVE INSTALL
1. Remove parts as shown. 1. Install parts as shown. I
/'-
With small screwdriver, pry
check valve from housing.
Care
should be taken not to
damage threads when prying
on edge of housing.
3/8 tubing, 4 inches
A Uslng spanner wrench
J-7624, tlghten adjuster
plug until thrust bearlng IS flrmly bottomed. 27 Newton
Metres (20 Ft Lbs )
Mark housing and
I I Measure back I counterclockw~se I 13 mm (l/zl') and place a f se~ond mark on housing 1
tlghten lock nut securely
Hold adjuster plug to J
malntain alignment of
I
Figure 387-1 7 Overhaul
13. PITMAN SHAR "OVER-CENTER"
SECTOR ADJUSTMENT
normally on same side as.
and parallel with, slde cover.
The block tooth on the
Pltman shaft IS In llne w~th the
over-center preload adjuster - /
B Back off preload adjuster I C Turn adjuster In unt~l untll ~t stops, then turn I torque to turn stub shaft ~t ~n one full turn 1 IS 0 6 to 1 2 Newton Metres 1 (6 to 10 In Lbs ) 1 more than readlng At1
1 I 7
L
1
With gear at center f Torque adjuster lock
of travel, check torque I nut to 27
to turn stub shaft 1 (20 Ft Lbs ) (readlng XI) I I Prevent adjuster screw I from turnlng whlle I torquelng lock nut
I I I
8001808 Gear, Chart F

POWER STEERING 387-17
POWER STEER ING PUMP
BT-7002-3
BT-7515
POWER STEER ING GEAR
5-2431 801 J-22407
J-517801 Pressure Testing Manifold J-7576 Rack-Piston Teflon Ring Compressor
End Cover Seal and Needle Bearing Installer
J-7624 Spanner Wrench
Hose Connector Installer
J-8947 Rack-Piston Teflon Ring Compreaor
Bearing Installer
5-21552 Ball Retainer
End Cover Seal Protector (Used for Installing
J-24319-01 Puller
Adjuster Plug)
5-22407 Pitman Bearing Installer
Pitman Shaft Bearing Remover and Installer J-22616 Seal Proteaor
5-6278-2 Adapter (Used with 5-6278 for Installing J-23600 Belt Tension Gage
Pitman Shaft Seals and Bearing)
J-25033 Power Steering Pump Pulley Insmller BT-7002-3 Belt Tension Gage 5-25034 Power Steering Pump Pulley Remover
5-7132.2 Seal Installer 5-29107 Pitman Arm Puller
BT-7515 Pulley Remover and lnstaller
J-29810 Stub Shaft Seal Protector
Figure 387-1 8 Special Tools