1993 CHEVROLET DYNASTY Service Manual

radiator cap oil additives maintenance CD player door lock bolt pattern

Page 1929 of 2438

CHEVROLET DYNASTY 1993 Service Manual INSTALL
(1) Install power steering pressure switch into fit-
ting on power steering pressure hose by hand until
fully seated. Then torque power steering pressure
switch to 12 N Im (106 in. lbs.).
(

INSTALL
(1) Install power steering pressure switch into fit-
ting on power steering pressure hose by hand until
fully seated. Then torque power steering pressure
switch to 12 N Im (106 in. lbs.).
(2) Install vehicle wiring harness connector onto
power steering pressure switch. Be sure latch on wir-
ing harness connector is fully engaged with locking
tab on power steering pressure switch.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(3) Fill power steering pump reservoir to correct
fluid level. (4) Connect negative cable back on negative post of
battery. (5) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
POWER STEERING HOSES
Service all power steering hoses with the vehicle
raised on a hoist. Cap all open ends of hoses, power
steering pump fittings and steering gear ports to pre-
vent entry of foreign material into the components.
WARNING: POWER STEERING OIL, ENGINE PARTS
AND EXHAUST SYSTEM MAY BE EXTREMELY HOT
IF ENGINE HAS BEEN RUNNING. DO NOT START
ENGINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW HOSES TO TOUCH HOT
EXHAUST MANIFOLD OR CATALYST.
For part reference and part location on the vehicle
being serviced, refer to Figs. 3 to 6. These show the
hose bracket locations, hose routings and fitting loca-
tions by the engine application of the vehicle. Use
these figure numbers when referring to the removal
or installation procedures for the power steering
hoses listed below.
REMOVAL
(1) Remove vehicle's wiring harness connector (if
applicable to vehicle being serviced) from the power
steering pressure switch (Fig .1&2).
(2) Remove bolts from power steering hose routing
brackets to crossmember attachment points. (3) Disconnect power steering hose at opening clos-
est to power steering gear assembly. Drain power
steering fluid from power steering pump and hose
through open end of hose. (4) Disconnect opposite end of hose and remove
power steering hose assembly from vehicle. (5) Discard O-ring or sealing washer located at end
of tube. (6) Remove power steering pressure switch, from
the removed power steering hose for installation into
the replacement power steering hose.
INSTALLATION
(1) Install the removed power steering pressure
switch into replacement power steering pressure
hose. Torque power steering pressure switch to 12
N Im (106 in. lbs.).
Fig. 3 Power Steering Hose Routing 2.2 & 2.5L
Fig. 4 Power Steering Hose Routing 3.0L
Ä STEERING 19 - 11

Page 1930 of 2438

CHEVROLET DYNASTY 1993 Service Manual (2) Using a lint free towel, wipe clean open power
steering hose ends, power steering pump and steer-
ing gear ports. (3) Install new O-rings or sealing washers on the
ends of the power steering hose

(2) Using a lint free towel, wipe clean open power
steering hose ends, power steering pump and steer-
ing gear ports. (3) Install new O-rings or sealing washers on the
ends of the power steering hoses. Lubricate O-rings
or sealing washers using clean power steering fluid. (4) Attach power steering hose to proper connec-
tions at power steering pump and steering gear. Cor-
rectly route power steering hoses avoiding tight
bends or kinking of the hose. Install power steering hose to crossmember routing bracket.
Hoses must
remain away from exhaust system, vehicle com-
ponents and unfriendly surfaces causing pos-
sible damage to power steering hoses. (5) Tighten all fasteners shown for specific applica-
tions in (Fig. 1 to 4) to their correct torques listed
below:
² Pump End Banjo Bolt Ð 34 N Im (25 ft. lbs.)
² Pump End Tube Nut Ð 34 N Im (25 ft. lbs.)
² Gear End Tube Nuts (2) Ð 34 N Im (25 ft. lbs.)
² Crossmember Bracket Bolt Ð 23 N Im (17 ft. lbs.)
² Pump Bracket Nut Ð 40 N Im (30 ft. lbs.)
² Gear Bracket Bolt Ð 68 N Im (50 ft. lbs.)
(6) Install vehicle's wiring harness connector (if ap-
plicable to vehicle being serviced) onto the power
steering pressure switch (Fig .1&2).
(7) When used, protective sponge sleeves must be
properly positioned on power steering hoses. This is to
prevent hose contact with other components. (8) After hose is installed, check for leaks. (See
Pump Installation).
POWER STEERING PUMP REMOVAL
WARNING: POWER STEERING OIL, ENGINE COMPO-
NENTS AND EXHAUST SYSTEM MAY BE EX-
TREMELY HOT IF ENGINE HAS BEEN RUNNING. DO
NOT START ENGINE WITH ANY LOOSE OR DISCON-
NECTED HOSES, OR ALLOW HOSES TO TOUCH HOT
EXHAUST MANIFOLD OR CATALYST.
2.2 & 2.5 LITER
REMOVE
(1) Remove battery cable from (-) negative post on
battery and isolate cable. (2) Loosen power steering pump adjustment bolt
and rotate power steering pump forward in bracket.
Remove power steering pump drive belt from power
steering pump (Fig. 1). It is not necessary to remove
power steering pump drive belt from engine. (3) Raise vehicle See Hoisting, Group 0. Remove
hose clamp and low pressure fluid hose from power
steering pump (Fig. 2). (4) Remove power steering fluid pressure line (Fig.
2) from power steering pump. Drain excess power
steering fluid from line. (5) Loosen but do not remove nut, holding back of
power steering pump to its mounting bracket (Fig. 3).
Then remove bolt attaching pulley side of power steer-
ing pump to the mounting bracket (Fig. 3). (6) Lower Vehicle. Then remove bolt, retaining
power steering pump in adjusting slot of power steer-
ing pump mounting bracket (Fig. 3). (7) Remove power steering pump from top of engine
compartment, using the following procedure.
Lifting power steering pump out of mounting
Fig. 5 Power Steering Hose Routing 3.3 & 3.8L
Fig. 6 Power Steering Hose Routing Turbo III
19 - 12 STEERING Ä

Page 1931 of 2438

CHEVROLET DYNASTY 1993 Service Manual bracket, rotating pump 90É and remove it out be-
tween engine and dash panel.(8) Transfer required parts from removed power
steering pump, to replacement power steering pump.
INSTALL
(1) Install p

bracket, rotating pump 90É and remove it out be-
tween engine and dash panel.(8) Transfer required parts from removed power
steering pump, to replacement power steering pump.
INSTALL
(1) Install power steering pump back in vehicle in
the reverse order of removal. (2) Install power steering pump back on mounting
bracket, being sure stud on back of power steering
pump is in slotted hole in mounting bracket. Install bolt attaching power steering pump to adjusting slot
in bracket (Fig. 3),
but do not tighten nut or bolt.
(3) Raise vehicle See Hoisting, Group 0.
(4) Install bolt attaching pulley side of power
steering pump to power steering pump mounting
bracket (Fig. 3). Do not fully tighten power steer-
ing pump mounting bolts at this time. (5) Install power steering fluid pressure line into
output fitting on power steering pump (Fig. 2).
Torque power steering pressure line tube nut to 31
N Im (275 in. lbs.). Before connecting pressure line
to power steering pump inspect O-ring on pres-
sure line for damage and replace if required. (6) Install power steering fluid, low pressure re-
turn hose on power steering pump low pressure fit-
ting (Fig. 2). Install hose clamp on low pressure
return hose, being sure hose clamp is installed on
hose past upset bead on power steering pump tube. (7) Lower vehicle.
(8) Install power steering pump drive belt on
power steering pump pulley. Using power steering
pump adjusting bracket (Fig. 1), rotate pump in
bracket to obtain correct belt tension. Tighten bolt at
power steering pump mounting bracket adjusting slot
(Fig. 1) to 54 N Im (40 ft. lbs.). Torque the power
steering pump to mounting bracket pivot, nut and
bolt (Fig. 1) to 54 N Im (40 ft. lbs.).
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(9) Fill power steering pump reservoir to correct
fluid level.
Fig. 1 Power Steering Pump Drive Belt Removal
Fig. 2 Power Steering Fluid Hoses
Fig. 3 Power Steering Pump Remove And Install
Ä STEERING 19 - 13

Page 1932 of 2438

CHEVROLET DYNASTY 1993 Service Manual (10) Connect negative cable back on negative post
of battery. (11) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid

(10) Connect negative cable back on negative post
of battery. (11) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.0 LITER
REMOVE
(1) REMOVE THE (-) NEGATIVE BATTERY CA-
BLE FROM THE BATTERY AND ISOLATE CA-
BLE. (2) Remove the serpentine accessory drive belt
from engine (Fig. 4). See Cooling, Group 7 for de-
tailed removal procedure.
(3) Remove the hose clamp and bolt mounting the
power steering pump filler tube and dipstick assem-
bly (Fig. 5) to power steering pump and generator
bracket. Remove filler tube and dipstick assembly
from power steering pump. (4) Raise vehicle See Hoisting, Group 0.
(5) Remove the 2 nut, bolt and spring assemblies
attaching the exhaust pipe to exhaust manifold. Re-
move exhaust pipe from exhaust manifold and move
to left side of vehicle. This is required for clear-
ance to remove power steering pump from vehi-
cle. (6) Remove vehicle's wiring harness connector (if
applicable to vehicle being serviced) from the power
steering pressure switch (Fig. 6). (7) Put oil drain pan under vehicle to catch power
steering fluid. Remove hose clamp and low pressure
fluid hose, from power steering gear fluid tube (Fig.
7). Allow excess power steering fluid to drain from
power steering pump and hose. (8) Loosen the high pressure power steering fluid
line fitting at the power steering pump (Fig. 7). Then
remove high pressure power steering fluid line from
power steering pump. (9) Remove nut holding the power steering pump
rear support bracket to pump (Fig. 8). Then remove
the 2 bolts (Fig. 7) mounting the power steering
pump support bracket to engine and remove bracket
from vehicle. (10) Remove the 2 bolts that mount the front of
the power steering pump to the mounting plate (Fig.
9). Access to the mounting bolts is through the holes
in power steering pump pulley using a deep well
socket. (11) Remove the power steering pump and pulley
assembly from vehicle. Remove pump assembly from
vehicle in area between floor pan and front suspen-
sion crossmember. Pump will fit through area of ex-
haust pipe tunnel in floor pan.
Fig. 4 3.0L Serpentine Drive Belt Routing
Fig. 5 Power Steering Pump Filler Tube/Dipstick Assembly
Fig. 6 Power Steering Pressure Switch Location 3.0L
19 - 14 STEERING Ä

Page 1933 of 2438

CHEVROLET DYNASTY 1993 Service Manual (12) Transfer Required parts to the new power
steering pump assembly before installing in vehicle.
INSTALL
(1) Install the power steering pump assembly back
in vehicle in reverse order of removal.

(12) Transfer Required parts to the new power
steering pump assembly before installing in vehicle.
INSTALL
(1) Install the power steering pump assembly back
in vehicle in reverse order of removal. (2) Hold power steering pump against mounting
plate. Align power steering pump mounting holes
with mounting holes in plate and install bolts (Fig.
9). Torque the 2 power steering pump to mounting
plate bolts to 54 N Im (40 ft. lbs.).
(3) Install the rear power steering pump to engine
block support bracket, onto the stud on back of power
steering pump (Fig. 8). Then install the 2 bolts
mounting the support bracket to the engine block.
Torque the 2 support bracket to engine block mount-
ing bolts to 54 N Im (40 ft. lbs.). (4) Install the nut on stud of power steering pump
attaching pump to rear support bracket (Fig. 8).
Torque nut to 54 N Im (40 ft. lbs.)
(5) Install the high pressure power steering fluid
line on the power steering pump outlet fitting (Fig.
7). Torque the high pressure fluid line to power
steering pump fitting to 31 N Im (275 in. lbs.).
(6) Install the low pressure power steering fluid
hose onto the power steering gear fluid tube (Fig. 7).
Install hose clamp on hose. Be sure hose clamp is
installed beyond upset bead on tube. (7) Install the exhaust pipe back on the exhaust
manifold. Install the nut, bolt and spring assemblies
and torque bolts to 28 N Im (250 in. lbs.).
(8) Install vehicle's wiring harness connector (if
applicable to vehicle being serviced) onto the power
steering pressure switch (Fig. 6). (9) Lower vehicle.
(10) Install the power steering pump filler tube
and dip stick assembly on the neck of the power
steering pump (Fig. 5). Install the bolt (Fig. 5) at-
taching the filler tube/dip stick assembly to the gen-
erator bracket, then torque bolt to 11 N Im (100 in.
lbs.). (11) Position the hose clamp on the filler tube as-
sembly rubber boot and adequately tighten hose
clamp. (12) Install the serpentine accessory drive belt on
engine (Fig. 4). See Cooling, Group 7 for detailed in-
stallation procedure.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(13) Fill power steering pump reservoir to correct
fluid level. (14) Connect the negative battery cable back on
the negative battery post.
Fig. 7 Power Steering Hose Remove/Replace
Fig. 8 Power Steering Support Bracket
Fig. 9 Power Steering Pump Mounting 3.0L
Ä STEERING 19 - 15

Page 1934 of 2438

CHEVROLET DYNASTY 1993 Service Manual (15) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level

Page 1935 of 2438

CHEVROLET DYNASTY 1993 Service Manual (12) Remove nut and bolt attaching the generator/
power steering pump bracket, support strut (Fig. 16). (13) Lower vehicle.
(14) Remove the 2 bolts holding the power steering
fluid reservoir to the

Page 1936 of 2438

CHEVROLET DYNASTY 1993 Service Manual INSTALL (1) Install power steering pump back in vehicle,
laying it on the steering gear. Do not mount it to the
power steering pump bracket. (2) Install generator back on the lower generator
bracket

INSTALL (1) Install power steering pump back in vehicle,
laying it on the steering gear. Do not mount it to the
power steering pump bracket. (2) Install generator back on the lower generator
bracket and install bolt and nut (Fig. 19). Do not
tighten bolt at this time. (3) Install the generator bracket back on engine and
intake manifold. Loosely install the 4 generator
bracket to engine attaching bolts (Fig. 19). Be sure
the SPACER (Fig. 18) is installed between the
engine mounting strut and the generator
bracket. (4) Temporarily install the serpentine belt tensioner
bolt through both generator brackets. This will align
all generator bracket mounting holes (Fig. 15). Then
torque the 4 generator bracket to engine and intake manifold mounting bolts to 54 N
Im (40 ft.
lbs.). Then remove the serpentine belt tensioner from
bracket. It will be installed on the bracket in a
later step. (5) Tighten the bolt holding the engine bracket as-
sembly to the engine support assembly (Fig. 18) to 150
N Im (110 ft. lbs.).
(6) Attach the engine wiring harness routing clip to
the generator bracket. (7) Install the generator to generator bracket attach-
ing bolt (Fig. 19). Torque bolt to 54 N Im (40 ft. lbs.).
Tighten the lower generator pivot bolt to 54 N Im (40 ft.
lbs.). (8) Install the power steering pump fluid reservoir
and tube/hose assembly onto the power steering pump
bracket and generator bracket (Fig. 17). Torque the 2
bolts holding the reservoir to the generator bracket to
5N Im (45 in. lbs.). Torque the 1 bolt holding the
tube/hose assembly to the power steering pump
bracket to 12 N Im (105 in. lbs.).
(9) Raise vehicle See Hoisting, Group 0.
(10) Install the strut assembly power
steering/generator bracket to engine (Fig. 16). Torque
the nut and bolt holding the strut assembly to bracket
and the exhaust manifold stud to 54 N Im (40 ft. lbs).
(11) Install the serpentine drive belt tensioner onto
the power steering/generator bracket (Fig. 15). Install
the tensioner to bracket retaining nut and torque to 54
N Im (40 ft. lbs.).
(12) Install the power steering pump on bracket, by
aligning the 3 mounting holes in pump with mounting
holes in bracket (Fig. 14). Install the 3 power steering
pump to bracket mounting bolts. Torque power steer-
ing pump mounting bolts to 54 N Im (40 ft. lbs.).
(13) Install the support strut, engine block to power
steering pump on pump stud (Fig. 14). Install the nut
and bolt holding the strut to the power steering pump
and engine block and torque to 54 N Im (40 ft. lbs.).
(14) Install the power steering fluid pressure line
onto the output fitting of the power steering pump (Fig.
12). Torque the pressure line pump fitting nut to 31
N Im (275 in. lbs.). Before connecting the pressure
line to power steering pump inspect the O-ring
on the pressure line for damage. (15) Install vehicle's wiring harness connector (if
applicable to vehicle being serviced) onto the power
steering pressure switch (Fig. 11). (16) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure
fitting (Fig. 12). Then install the hose from the remote
reservoir onto the power steering pump (Fig. 13). Be
sure all hose clamps are properly reinstalled. (17) Install right front tire and wheel on vehicle.
Install the wheel stud nuts and torque to 129 N Im (95
ft. lbs.).
Fig. 18 Engine Bracket Support Assembly
Fig. 19 Generator Mounting
19 - 18 STEERING Ä

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