Power Steering Bleeding Chevrolet Astro I

Note. If air was introduced into hydraulic system during servicing, bleed system. Aerated fluid, which appears Light Tan in color, results in poor steering performance and will cause pump damage.

1. Turn ignition off. Raise and support vehicle with front wheels off ground. Using steering wheel, turn wheels fully to left. Add power steering fluid to FULL COLD mark on dipstick. Turn wheels from side to side at least 20 times, but DO NOT touch steering stops. Add fluid as necessary to maintain level at FULL COLD mark.
2. Start engine. With engine idling, check fluid level. Add fluid as necessary to bring fluid level to FULL COLD mark. Return wheels to center position. Lower vehicle. Continue to run engine for 2 to 3 minutes to raise temperature of fluid and eliminate trapped air. Turn steering wheel in both directions.
3. Road test vehicle. Check for leaks. Ensure fluid level is at FULL HOT mark when fluid is stabilized at operating temperature.

Removal

Note. This procedure must be done on a side post hoist, or a twin post hoist, using Adapter assembly (J-41617), if available. (Scheme 1)

1. On this vehicle, engine must be removed out of bottom of vehicle. Release fuel system pressure. See «FUEL PRESSURE RELEASE»(ref-50103-S19297080802001011600000). Recover A/C refrigerant, if equipped. See appropriate article in REFRIGERANT RECOVERY/RECYCLING in A/C GENERAL SERVICING. Remove battery. Remove air filter assembly and if equipped, disconnect cruise control cable from throttle body. Disconnect cruise control stepper motor electrical connector. Disconnect accelerator cable. Drain cooling system. Remove interior engine cover. Raise and support vehicle. Drain engine oil.
2. Remove drive shaft. Disconnect transfer case vent hose. Disconnect exhaust pipes from manifolds and behind catalytic converter. Remove park brake bracket from frame. Disconnect rear brake line from metering proportioning valve (combination valve). Remove flywheel cover, 3 torque converter bolts (A/T), starter and oil filter. Disconnect shift linkage. Disconnect engine wiring harness from transmission and frame.
3. Disconnect fuel lines from sub-frame. Disconnect transmission fluid lines and engine oil cooler lines from radiator, remove fan shrouds and remove radiator. Disconnect power steering cooler from front air deflector. Disconnect air bag sensor connector. Remove motor mount through-bolts. Lower vehicle. Remove front bumper.
4. Remove headlight bezels and grille. Remove lower radiator close-out panel, radiator support braces and radiator cross brace. Remove hood latch mechanism.
5. Remove radiator filler panels. Disconnect A/C hose from accumulator and condenser. Remove A/C compressor and bracket. Remove power steering pump and drain. Disconnect lines to hydro boost unit. Disconnect master cylinder from hydro boost and tie to oil fill tube. Disconnect steering shaft. Disconnect wheel housing splash shields. If equipped, disconnect rear A/C lines at rear crossmember.
6. Disconnect vacuum hoses as necessary. Disconnect fuse box and wiring harness from bulkhead connector and all related electrical connectors. Lay harness on engine. Remove right kick panel. Remove CPI or TBI unit from intake manifold. Push connector and harness through firewall. Remove distributor cap and A/C accumulator. Disconnect fuel line from injection unit.
7. Remove transmission dipstick tube (A/T). Disconnect heater hose from heater core. Remove horn. Attach side lift hoist. Attach Body Protection Hoist Adapter Set (J41602), or Twin Post Hoist Frame Support (J41617), if necessary, and Universal Lift Bracket (J41427), raise vehicle. (Scheme 1) Support transmission. Pull fuel lines through crossmember and lay lines on transmission. Disconnect A/T linkage. Remove fuel tank electrical connector. Disconnect necessary brake line fittings. On 4WD, disconnect transfer case to engine block support brace. Remove bellhousing and sub-frame bolts. Using appropriate jack or hoist, lower engine/sub-frame assembly from vehicle. Remove engine from sub-frame assembly.

Scheme 1

Note. If a NEW engine is installed, ensure all brackets and accessories are transferred to NEW engine prior to installation.

1. Place engine in position on sub-frame. Install engine mount through bolts. Torque to specification. See «TORQUE SPECIFICATIONS»(ref-50103-S06511345062001011600000). Remove engine lift Adapter (J-41427).
2. Connect transmission to engine, torque to specification. See «TORQUE SPECIFICATIONS»(ref-50103-S06511345062001011600000). Install exhaust "Y" pipe to engine. On 4WD models, install transfer case support brace. Route and connect all fuel lines, hoses and transmission wiring harness. Connect steering shaft and wheel housing splash shields.
3. Install distributor cap. Connect heater hose from coolant pump. Connect harness at knock sensor module. Connect wiring harness at bulkhead. Install CPI or TBI unit to intake manifold. Install A/C compressor.
4. Lower vehicle into position for engine/sub-frame installation. Install sub-frame bolts and tighten in sequence. (Scheme 1) Connect engine electrical harness. Route and install remaining accessory, bulkhead and fuse box wiring. Secure fuse box. Connect wheel housing splash shields to frame. Install steering shaft and torque to specification. See «TORQUE SPECIFICATIONS»(ref-50103-S06511345062001011600000). Install power steering pump bracket and pump. Connect A/C compressor hose assembly. Install cruise control servo and bracket.
5. Connect power steering pump. Connect hydraulic lines at gear-box, pump, hydro boost and reservoir. Install serpentine belt. Install/connect A/C accumulator and hoses. Install radiator. Install upper radiator hoses and cooler lines. Connect heater hoses. Install all vacuum hoses.
6. Install fan and fan clutch assembly. Install fan shroud and radiator filler panels. Install grille and headlamp bezels.
7. Install master cylinder and connect all fittings disconnected previously. Install hood latch and radiator braces. Install transmission and engine filler tubes. Install cruise control stepper motor cable, wiring and accelerator cable. Install plug wires.
8. Install air cleaner and ducts. Connect fuel lines at intake manifold. Install fuel line bracket and connect fuel lines at frame. Raise and support vehicle with safety stands.
9. Connect lower engine oil cooler line to radiator. Install power steering cooler and lines. Install lower transmission oil cooler line and lower radiator hose to radiator. Install front bumper. Connect drive shaft and transmission linkage. Torque all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-50103-S06511345062001011600000). Connect all fuel hoses. Install air bag sensor wiring. Install starter. Connect remaining wiring at engine and sub-frame.
10. Install torque converter bolts and cover. See «TORQUE SPECIFICATIONS»(ref-50103-S06511345062001011600000). Connect exhaust pipes and lower vehicle. Install oil filter and oil. Ensure oil level is correct. See «CRANKCASE CAPACITY»(ref-50103-S21937108242001011600000). Ensure transmission fluid level is correct. Fill and bleed power steering system. See «POWER STEERING BLEEDING»(ref-50103-S05320776832001121400000). Install air filter assembly. Install battery and negative battery cable. Install engine cover. Install right kick panel.
11. Install battery. Fill and bleed brake system. Install coolant as needed. See «COOLING SYSTEM BLEEDING»(ref-50103-S33609718192001121400000). Evacuate and charge A/C system. See appropriate article in REFRIGERANT RECOVERY/RECYCLING in A/C GENERAL SERVICING.
12. Check all components for leaks, proper fluid levels and proper operation.