SMU-SEC. 3B1-REVISED POWER STEERING PUMP REM/INSTALL

SUBJECT: SERVICE MANUAL UPDATE - SECTION 3B1 - REVISED POWER STEERING PUMP REMOVE/INSTALL PROCEDURE

MODELS: 1996-97 GEO TRACKER

THIS BULLETIN IS BEING ISSUED TO REVISE THE POWER STEERING PUMP REMOVE/INSTALL PROCEDURE IN SECTION 3B1 OF THE SERVICE MANUAL.

PLEASE REPLACE THE CURRENT PROCEDURE WITH THE FOLLOWING:

UNIT REPAIR PROCEDURE:

POWER STEERING PUMP

REMOVE

1. REMOVE THE POWER STEERING PUMP FROM THE VEHICLE. REFER TO POWER STEERING PUMP. (FIGURE 1).

NOTICE:

USE CAUTION NOT TO OVERTIGHTEN THE VISE. THE POWER STEERING PUMP HOUSING CAN DISTORT IF EXCESSIVE PRESSURE IS EXERTED ON ITS EXTERIOR.

2. MOUNT THE PUMP IN A SOFT JAW VISE.

3. REMOVE THE SUCTION HOSE CONNECTOR BOLT, THE CONNECTOR AND THE O-RING FROM THE PUMP BODY.

4. REMOVE THE PRESSURE SWITCH AND DISCHARGE CONNECTOR ASSEMBLY (1) FROM THE PUMP. (FIGURE 2).

5. REMOVE THE DISCHARGE CONNECTOR (1) AND FLOW CONTROL VALVE (2) ASSEMBLY FROM THE PUMP (FIGURE 3).

6. REMOVE THE FOUR BOLTS, THE REAR PUMP COVER (2) AND THE O-RING SEAL (1) FROM THE PUMP (FIGURE 4).

7. REMOVE THE VANES (2) FROM THE ROTOR (FIGURE 5).

8. REMOVE THE SNAP RING, THE ROTOR (2) AND THE CAM RING FROM THE PUMP (FIGURE 6).

9. REMOVE THE SHAFT (1) WITH THE PULLEY ATTACHED, THE SIDE PLATE AND THE OIL SEAL FROM THE PUMP (FIGURE 6).

MEASURE

- MEASURE THE VANE TO ROTOR CLEARANCE USING A FEELER GAGE (1). THE MAXIMUM VANE TO ROTOR CLEARANCE IS 0.06 (0.0023 IN.). IF THE VANE TO ROTOR CLEARANCE IS GREATER THAN SPECIFIED, REPLACE THE PUMP ASSEMBLY. (FIGURE 7).

- MEASURE THE FREE LENGTH OF THE FLOW CONTROL VALVE SPRING (1) USING DIAL CALIPERS. THE FREE LENGTH OF THE SPRING SHOULD FALL WITHIN 30.5 MM - 33.5 MM (1.20 IN. TO 1.32 IN.). IF THE VALVE SPRING DOES NOT FALL WITHIN THE SPECIFICATIONS, REPLACE THE PUMP ASSEMBLY (FIGURE 8).

INSPECT

- INSPECT THE PUMP BODY, THE CAM RING, THE ROTOR, THE VANES AND THE FLOW CONTROL VALVE FOR EXCESSIVE WEAR. (FIGURE 9)

- INSPECT THE POWER STEERING PUMP BODY FOR CRACKS OR LEAKS. IF EXCESSIVE WEAR, CRACKS OR LEAKS ARE PRESENT ON THE PUMP BODY OR THE INTERNAL PARTS, THE POWER STEERING PUMP MUST BE REPLACED. (FIGURE 10).

INSTALL

IMPORTANT:

- REPLACE ALL OLD POWER STEERING PUMP O-RING SEALS WITH NEW ONES FROM THE POWER STERING PUMP SEAL KIT.

- LUBRICATE THE INTERNAL PARTS WITH POWER STEERING GEAR AND PUMP FLUID DEXRON(R)-III, OR EQUIVALENT.

1. INSTALL THE OIL SEAL, THE PULLEY WITH THE SHAFT ATTACHED AND THE SIDE PLATE (2) TO THE POWER STEERING PUMP. (FIGURE 11).

2. INSTALL THE CAM RING, THE ROTOR (2) AND THE SNAP RING TO THE PUMP. (FIGURE 12).

3. INSTALL THE VANES TO THE ROTOR.

4. INSTALL A NEW O-RING SEAL AND REAR PUMP COVER TO THE PUMP. SECURE WITH THE FOUR BOLTS.

IMPORTANT:

- AFTER INSTALLING THE COVER, CHECK TO MAKE SURE THAT THE SHAFT CAN BE TURNED BY HAND.

TIGHTEN

- TIGHTEN THE POWER STEERING PUMP REAR COVER/CAM RING BOLTS TO 24 N.M (17.5 LB FT).

5. INSTALL THE FLOW CONTROL VALVE ASSEMBLY AND THE DISCHARGE CONNECTOR (1) TO THE PUMP. (FIGURE 13).

TIGHTEN

- TIGHTEN THE POWER STEERING PUMP DISCHARGE CONNECTOR TO 66 N.M (48 LB FT.)

6. INSTALL THE PRESSURE SWITCH (1) TO THE PUMP. (FIGURE 14).

TIGHTEN

- TIGHTEN THE POWER STEERING PUMP PRESSURE SWITCH TO 18 N.M (13.5 LB FT).

7. INSTALL A NEW O-RING AND THE SUCTION HOSE CONNECTOR TO THE PUMP. SECURE WITH THE BOLT.

TIGHTEN

- TIGHTEN THE POWER STEERING PUMP SUCTION HOSE CONNECTOR BOLT TO 10 N.M (89 LB IN).

8. INSTALL THE POWER STEERING PUMP TO THE VEHICLE. REFER TO POWER STEERING PUMP. (FIGURE 15).

FIGURES: 15 ATTACHMENTS: 00

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.

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