Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Power Steering Gear Special tools, testers and auxiliary items required Hose clamps up to 25 mm dia. 3094 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 Notes for repair work on power steering gear All work on the power steering must be carried out with utmost cleanliness. Thoroughly clean all connections and the surrounding area before disconnecting. If repairs will not be carried out immediately, place removed parts onto a clean surface and cover. Only use lint-free cloths. Only unpack replacement parts immediately prior to installation. Only use parts in their original packing. Removing Remove bolts – 1 – . Remove cover – A – . Remove bolt – 1 – from universal joint. Remove universal joint from steering gear. Clamp off hose from reservoir using hose clamps up to 25 mm dia. 3094 . Clamp off hose on power steering pump using hose clamps up to 25 mm dia. 3094 . Remove sound-deadening pan. Place drip tray underneath. . Press off tie rod from steering knuckle. A – Tie rod puller (standard), e.g. Kukko 128/2 Remove hose lines at steering gear and plug using a plastic bag and tape. Seal threaded holes on power steering gear using plastic screw plugs – 1 – and – 2 – . Remove bolts – 1 – and – 2 – . With TDI Engines Remove bracket for front exhaust pipe at subframe – arrows – and disengage. Continuation for All Support subframe using engine/transmission jack V.A.G 1383 A . Loosen bolts – 1 – . Remove bolts – 2 – and – 3 – . Lower subframe using engine/transmission jack V.A.G 1383 A . Remove bolts – 1 – for power steering gear. Remove power steering gear toward right. Installing Note: . Use new O-rings for hose/line connections. Coat seal on steering gear with lubricant, e.g. lubricating soap, before installing steering gear. After placing steering gear on to universal joint shaft, make sure that seal on steering gear makes contact on assembly plate without kinks and opening to footwell is correctly sealed. Ingress of water and/or noises may result otherwise. Make sure sealing surfaces are clean.

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Removal and Installation 1. Rotate the tensioner clockwise and remove the belt from the power steering pump pulley. 2. Loosen the fitting and disconnect the power steering pressure hose. 3. Disconnect the electrical connector. 4. Disconnect the power steering return line. 5. Using the special tool, remove the power steering pump pulley. 6. Remove the power steering pump mounting bolts and the pump. 7. To install, reverse the removal procedure. 8. NOTE: The pulley must be installed within 0.25 mm (0.010 in) flush with the power steering pump shaft. Using the special tool, install the power steering pump pulley. 9. Using the special tool, install a new seal on the power steering pressure hose fitting. 10. Fill and leak check the system. For additional information, refer to Section 211-00.

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Removal All Vehicles 1. Disconnect the battery ground cable. 2. Center the steering wheel. Lock in position, remove the ignition key. 3. Disconnect the steering column shaft from the flexible coupling. Rotate the clamp plate to disengage. 4. CAUTION: When removing the floor seal do not damage the sealing clips. Remove the floor seal from the bulkhead. 1. Release the retaining clips. 2. Disconnect the upper retaining clip. 3. Remove the floor seal. 5. Loosen the left-hand side front wheel nuts. 6. Raise and support the vehicle. For additional information, refer to Section 100-02. 7. Remove the wheel. 8. Remove the radiator splash shield. 9. Disconnect the fluid cooler line. Allow the fluid to drain into a suitable container. 10. Lower the vehicle. Vehicles with 2.0L engine 11. Detach the high-pressure tube support bracket. 12. Detach the high-pressure tube. Disconnect the power steering pressure (PSP) switch electrical connector. Detach the tube support bracket. Cut the three cable ties. 14. Remove the accessory drive belt. For additional information, refer to Section 303-05. 15. Lower the vehicle. 16. Detach the coolant hose clamp. 17. Detach the coolant expansion tank. Position the tank to one side. 18. Using the special tool, remove the power steering pump pulley. 19. Disconnect the power steering pump high-pressure tube union. Allow the fluid to drain into a suitable container.

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General Motors has decided that certain 2004 model year Chevrolet Malibu and Malibu Maxx vehicles may have been built with a steering column sensor that can wear unevenly and produce an erratic electrical signal. When the system software detects that erratic signal, power steering assist is lost. That signal is more likely to occur when the steering wheel is turned slowly. If this occurs, the driver will hear a chime, the Service Vehicle Soon light will illuminate, and the Driver Information Center will display “Power Steering.” Steering control is still maintained, although more effort is required at low speeds. The next time the vehicle is started, the power steering assist usually returns to normal and the lights in the instrument panel will be turned of{ but loss of assist can occur again until repairs are made.

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SYMPTOM The power steering pump whines, buzzes, or hums after driving for 30 minutes in temperatures of 35 to 40 degrees F (2 to 5 degrees C). PROBABLE CAUSE The power steering pump reservoir is defective. CORRECTIVE ACTION Flush the power steering system with clean power steering fluid, then replace the power steering reservoir. DIAGNOSIS 1. Run the engine until it reaches normal operating temperature (the cooling fans cycle twice). 2. Listen for abnormal noises from the power steering pump while the steering wheel is centered and not being turned. • If the pump whines, buzzes, or hums, go to REPAIR PROCEDURE. • If the noise is not coming from the pump, this service bulletin does not apply. Check for other possible causes of the noise. 3. Inspect the power steering reservoir. Is there a white dot on the reservoir cover, with one of its ribs pointing toward the reservoir holder? Yes – This vehicle already has the revised power steering reservoir. Continue with normal troubleshooting procedures. No – Go to REPAIR PROCEDURE. POWER STEERING RESERVOIR COVER 2. Drain the fluid from the power steering system: • Connect a suitable diameter drain hose to the disconnected return hose. • Hold the end of the drain hose in a suitable container. • Start the engine, and run it at idle while you turn the steering wheel lock-to-lock several times. • When the fluid stops running out of the hose, shut off the engine. • Discard the used fluid.