Power Steering System: Removal & Installation Chevrolet Uplander I

Removal Procedure

1. Remove the drive belt from the power steering pump pulley. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) for the 3.5L engine or «Drive Belt Replacement»(ref-241744-S07589734552006081100000) for the 3.9L engine.
2. Remove the power steering hoses from the power steering hose retainers.
3. Remove the bolts from the power steering pump. Refer to «Power Steering Pump Replacement»(ref-241712-S09659272492006081100000) .
4. Raise the power steering pump from the engine and rotate it enough to gain tool clearance.
5. Use J 37609-A to remove the pump pulley. See «Special Tools»(ref-241712-S35849504892006081100000) .

Installation Procedure

1. Use J 25033-C to install the power steering pump pulley. See «Special Tools»(ref-241712-S35849504892006081100000) .
2. Position the power steering pump to the engine and install the bolts. Refer to «Power Steering Pump Replacement»(ref-241712-S09659272492006081100000) .
3. Install the power steering hoses to the power steering hose retainers.
4. Install the drive belt to the power steering pump pulley. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) for the 3.5L engine or «Drive Belt Replacement»(ref-241744-S07589734552006081100000) for the 3.9L engine.
5. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-241712-S02881268322006081100000) .

1. Remove the accessory drive belt from the power steering pump pulley. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) for the 3.5L engine or «Drive Belt Replacement»(ref-241744-S07589734552006081100000) for the 3.9L engine.
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-241709-S28855367532006081100000) for the 3.5L engine or «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) for the 3.9L engine.
3. Disconnect the power steering pressure hose from the pump.
4. Disconnect the power steering return hose from the pump.
5. Remove the engine electrical harness from the reservoir retainers.
6. Remove the power steering pump mounting bolts.
7. Remove the power steering pump from the vehicle.
8. Remove the power steering pump pulley from the pump. Refer to «Power Steering Pulley Replacement»(ref-241712-S27082289232006081100000) .
9. Remove the reservoir from the pump. Refer to «Power Steering Reservoir Replacement - Off Vehicle (CB Series)»(ref-241712-S23902004822006081100000) .

1. Install the reservoir to the pump. Refer to «Power Steering Reservoir Replacement - Off Vehicle (CB Series)»(ref-241712-S23902004822006081100000) .
2. Install the power steering pump pulley. Refer to «Power Steering Pulley Replacement»(ref-241712-S27082289232006081100000) .
3. Install the pump to the vehicle.
4. Install the power steering pump bolts. Tighten: Tighten the bolts to 34 N.m (25 lb ft).
5. Connect the power steering return hose to the pump.
6. Connect the power steering pressure hose to the pump. Tighten: Tighten the fitting to 27 N.m (20 lb ft).
7. Install the engine electrical harness to the reservoir retainers.
8. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(ref-241709-S28855367532006081100000) for the 3.5L engine or «Intake Manifold Cover Replacement»(ref-241744-S09033023412006081100000) for the 3.9L engine.
9. Install the accessory drive belt to the power steering pump pulley. Refer to «Drive Belt Replacement»(ref-241709-S17523451682006081100000) for the 3.5L engine or «Drive Belt Replacement»(ref-241744-S07589734552006081100000) for the 3.9L engine.
10. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-241712-S02881268322006081100000) .

1. Remove the power steering pump from the vehicle, if necessary. Refer to «Power Steering Pump Replacement»(ref-241712-S09659272492006081100000) .
2. Use a small chisel in order to remove the seal. Discard the seal.

1. Lubricate the new drive shaft seal using power steering fluid.
2. Use a deep socket in order to install the new drive shaft seal.
3. Install the power steering pump, if removed. Refer to «Power Steering Pump Replacement»(ref-241712-S09659272492006081100000) .

1. Loosen the tie rod jam nut (2).
2. Remove the tie rod ball stud nut.
3. Use the J 24319-B to separate the outer tie rod from the steering knuckle. See «Special Tools»(ref-241712-S35849504892006081100000) .
4. Remove the outer tie rod (3) from the inner tie rod (1).

1. Install the outer tie rod (3) to the inner tie rod (1). Do not tighten the tie rod jam nut (2).
2. Install the outer tie rod (2) to the steering knuckle (1).
3. Install the tie rod ball stud nut. Tighten: Tighten the tie rod ball stud nut to 30 N.m (22 lb ft) + 120 degrees.
4. Inspect and adjust the toe as necessary. Refer to «Front Toe Adjustment»(ref-241714-S41543568092006081100000) in Wheel Alignment.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the right side engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
3. Place the drain pan under the power steering pump and the power steering gear.
4. Disconnect the return hose from the cooler pipe.
5. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
6. Use a utility stand in order to support the frame rear.
7. Remove the rear frame bolts.
8. Use the utility stand to lower the rear of the frame for clearance.
9. Remove the power steering gear heat shield and hose clip.
10. Disconnect the cooler pipe from the steering gear.
11. Remove the cooler pipe retainer bolt/screw.
12. Remove the cooler pipe retainer.
13. Remove the cooler pipe from the frame retainers and vehicle.

1. Install the cooler pipe to the vehicle and the frame retainers.
2. Install the cooler pipe retainer to the frame. Tighten: Tighten the cooler pipe retainer bolt/screw to 10 N.m (89 lb in).
3. Connect the cooler pipe to the steering gear. Tighten: Tighten the fitting to 27 N.m (20 lb ft).
4. Install the power steering gear hose clip.
5. Connect the power steering return hose to the cooler pipe.
6. Raise the frame rear position.
7. Install the rear frame bolts. Tighten: Tighten the bolts to 165 N.m (122 lb ft).
8. Remove the utility stand.
9. Connect the intermediate shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
10. Install the right side engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
11. Lower the vehicle.
12. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-241712-S02881268322006081100000) .

1. Place the drain pan under the power steering pump and the power steering gear.
2. Remove the drive belt. Refer to «Drive Belt Tensioner Diagnosis»(ref-241709-S23081782872006081100000) .
3. Disconnect the power steering pressure hose from the pump.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
5. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
6. Use a utility stand in order to support the rear of the frame.
7. Remove the frame rear bolts.
8. Lower the frame rear to gain clearance.
9. Remove the power steering gear heat shield. Refer to «Power Steering Gear Heat Shield Replacement»(ref-241712-S24640446892006081100000) .
10. Remove the power steering gear hose clip.
11. Disconnect the power steering pressure hose from the steering gear.
12. Remove the power steering hose from the hose retainer.
13. Remove the power steering pressure hose.

1. Install the power steering pressure hose.
2. Install the power steering hose to the hose retainer.
3. Install the power steering hose retainer to the power steering gear.
4. Connect the power steering hose to the steering gear. Tighten: Tighten the fitting to 27 N.m (20 lb ft).
5. Install the power steering gear hose clip.
6. Install the power steering gear heat shield. Refer to «Power Steering Gear Heat Shield Replacement»(ref-241712-S24640446892006081100000) .
7. Use the utility stand in order to raise the frame rear.
8. Install the frame rear bolts. Tighten: Tighten the bolts to 165 N.m (122 lb ft).
9. Remove the utility stand.
10. Install the intermediate shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
11. Lower the vehicle.
12. Connect the power steering pressure hose to the pump. Tighten: Tighten the fitting to 27 N.m (20 lb ft).
13. Install the drive belt. Refer to «Drive Belt Tensioner Diagnosis»(ref-241709-S23081782872006081100000) in Engine Mechanical - 3.5L.
14. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-241712-S02881268322006081100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the right side engine splash shield in order to gain access. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
3. Place the drain pan under the vehicle in order to catch any draining power steering fluid.
4. Remove the return hose from the power steering gear cooler pipe.
5. Lower the vehicle.
6. Remove the drive belt. Refer to «Drive Belt Tensioner Diagnosis»(ref-241709-S23081782872006081100000) in Engine Mechanical - 3.5L.
7. Remove the inlet hose from the power steering pump.
8. Remove the inlet hose from the hose retainer.
9. Remove the inlet hose.

1. Install the inlet hose.
2. Install the inlet hose to the hose retainer.
3. Install the inlet hose to the power steering pump.
4. Install the inlet hose to the power steering gear cooler pipe.
5. Install the right side engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
6. Lower the vehicle.
7. Install the drive belt. Refer to «Drive Belt Tensioner Diagnosis»(ref-241709-S23081782872006081100000) in Engine Mechanical - 3.5L.
8. Fill the power steering fluid reservoir. Refer to «Fluid and Lubricant Recommendations»(ref-241726-S27699792622006081100000) in Maintenance and Lubrication.
9. Bleed the power steering system. Refer to «Bleeding the Power Steering System»(ref-241712-S02881268322006081100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
2. If the vehicle is equipped with all wheel drive, remove the right side engine splash shield in order to access the heat shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
3. Remove the steering gear heat shield bolts.
4. Remove the steering gear heat shield.

1. Install the steering gear heat shield.
2. Install the steering gear heat shield bolts. Tighten: Tighten the steering gear heat shield bolts to 14 N.m (124 lb in).
3. If the vehicle is equipped with all wheel drive, install the right side engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
4. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the stabilizer shaft. Refer to «Stabilizer Shaft Replacement (FWD)»(ref-241710-S13642053022006081100000) or «Stabilizer Shaft Replacement (AWD)»(ref-241710-S00902690242006081100000) in Front Suspension.
3. Disconnect the tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-241712-S26292995872006081100000) .
4. Disconnect the steering intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
5. Use a utility stand in order to support the frame.
6. Remove the frame rear bolts.
7. Use the utility stand in order to lower the frame and the powertrain.
8. Remove the power steering gear heat shield. Refer to «Power Steering Gear Heat Shield Replacement»(ref-241712-S24640446892006081100000) .
9. Disconnect the power steering gear cooler pipe from the steering gear.
10. Disconnect the power steering gear pressure hose from the power steering gear.
11. Remove the power steering gear bolts and nuts.
12. Remove the power steering gear through the vehicle left side wheel opening.

1. Install the power steering gear through the vehicle left side wheel opening to the frame.
2. Install the power steering gear bolts.
3. Install the power steering gear nuts. Tighten: Tighten the power steering gear nuts to 60 N.m (44 lb ft) plus 60 degrees.
4. Install the power steering gear heat shield. Refer to «Power Steering Gear Heat Shield Replacement»(ref-241712-S24640446892006081100000) .
5. Connect the power steering gear pressure hose to the power steering gear. Tighten: Tighten the fitting to 27 N.m (20 lb ft).
6. Connect the power steering gear cooler pipe to the power steering gear. Tighten: Tighten the fitting to 27 N.m (20 lb ft).
7. Install the power steering gear cooler pipe retaining clip.
8. Use the utility stand in order to raise the frame and the powertrain.
9. Install the frame rear bolts. Tighten: Tighten the bolts to 165 N.m (122 lb ft).
10. Remove the utility stand from the frame.
11. Install the steering intermediate shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
12. Install the tie rod ends to the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-241712-S26292995872006081100000) in Power Steering System.
13. Install the stabilizer shaft. Refer to «Stabilizer Shaft Replacement (FWD)»(ref-241710-S13642053022006081100000) or «Stabilizer Shaft Replacement (AWD)»(ref-241710-S00902690242006081100000) in Front Suspension.
14. Lower the vehicle.
15. Fill the power steering system. Refer to «Checking and Adding Power Steering Fluid»(ref-241712-S22482045442006081100000) .
16. Bleed the air from the system. Refer to «Bleeding the Power Steering System»(ref-241712-S02881268322006081100000) .
17. Inspect the system for leaks. Refer to «Power Steering Fluid Leaks»(ref-241712-S14728971572006081100000) .
18. Inspect and adjust the toe as necessary. Refer to «Front Toe Adjustment»(ref-241714-S41543568092006081100000) in Wheel Alignment.