Power steering pump - removal and refitting
Note: New power steering fluid hose O-rings will be required when refitting.
All engines except 1.8 litre (R6A)
CVH and 2.0 litre DOHC
1 Place a suitable container under the power steering pump, unscrew the fluid hose unions, and drain the fluid. Ensure that fluid is not allowed to spill onto the alternator.
2 Remove the drivebelts and unbolt the power steering pump pulley if necessary to ease removal.
3 Unbolt the rear support bar from the pump and the engine block (see illustration).
29.3 Power steering pump rear support bar bolts (arrowed)
4 Unbolt the pump from its mounting bracket, and withdraw the pump from the engine.
5 Refitting is a reversal of removal, noting the following points.
6 Tension the drivebelts correctly.
7 When refitting the fluid hoses, use new O-rings, and take care not to overtighten the unions.
8 On completion of refitting, bleed the power steering fluid circuit.
1.8 litre (R6A) CVH engine 9 The removal and refitting procedures are basically the same as described below for the 2.0 litre DOHC engine, except that the pump is mounted on a bracket above the alternator on the front left-hand side of the engine.
2.0 litre DOHC engine
10 The pump is mounted on a bracket on the front right-hand side of the cylinder block.
11 Place a suitable container under the pump, unscrew the fluid pipe unions, and drain the fluid.
12 Remove the drivebelt which also drives the coolant pump and alternator.
13 Prevent the pulley from rotating using a strap wrench (which can be improvised using an old drivebelt and a large socket and wrench), and unscrew the three pulley securing bolts. Withdraw the pulley.
14 Unscrew the three pump securing bolts from the front of the pump bracket, and the single bolt from the rear of the bracket, and withdraw the pump (see illustrations).
29.14a Unbolt the power steering pump pulley for access to the front pump securing bolts (arrowed)
29.14b Power steering pump rear securing bolt
15 Refitting is a reversal of removal, bearing in mind the following points.
16 Reconnect the fluid unions using new Orings.
17 On completion, bleed the power steering fluid circuit.
Power steering fluid hoses - removal and refitting
Note: New fluid hose O-rings will be required when refitting.
1 Clean around the hose unions on the steering gear. Place a suitable container beneath the steering gear, then remove the single bolt securing the hoses to the pinion housing, unscrew the hose unions and drain the power steering fluid.
2 Clean around the hose unions on the pump.
Place a suitable container beneath the pump, unscrew the hose unions, and drain any remaining fluid. Ensure that no fluid is allowed to spill onto the alternator.
3 If the hoses are to be left disconnected for a long period of time, plug the ends of the hoses and the apertures in the steering gear and pump, or cover them with masking tape to prevent dirt ingress.
4 Refit in reverse order using new O-rings.
5 On completion top-up the fluid and bleed the system.
Power steering fluid circuit - bleeding
1 Unscrew the filler cap from the power steering pump reservoir and top-up the fluid level to the maximum mark using the specified fluid.
2 Disconnect the low tension negative lead from the ignition coil and crank the engine several times for two second periods while slowly turning the steering wheel from lock-to-lock. Top-up the fluid level if necessary and continue cranking the engine until the fluid is free of air bubbles.
3 Reconnect the coil lead and start the engine. Check the system for leaks.
4 Switch off the engine and refit the filler cap.
5 Drive the vehicle for a few miles to warm up the fluid and expel any remaining air, then stop the engine and make a final fluid level check.
Steering gear rubber gaiter - renewal
1 Remove the tie-rod end.
2 Unscrew and remove the tie-rod end locknut from the tie-rod.
3 Remove the clips and slide the gaiter from the tie-rod and steering gear.
4 Slide the new gaiter over the tie-rod and onto the steering gear. Where applicable, make sure that the gaiter seats in the cut-outs in the tie-rod and steering gear.
5 Secure the gaiter with new clips.
6 Refit the tie-rod end locknut to the tie-rod.
7 Refit the tie-rod end.
Throttle cable - adjustment, removal and refitting
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Turbocharger-to-manifold nut check - RS Turbo models (Every 12
000 miles or 12 months)
Check the tightness of the turbocharger-toexhaust manifold securing nuts using a torque wrench. ...