1993 CHEVROLET PLYMOUTH ACCLAIM power steering

(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.
3.3 & 3.8 LITER
REMOVE
(1) Remove the (-) negative battery cable from the
battery and isolate cable. (2) Remove the serpentine accessory drive belt
from engine (Fig. 10). See Cooling, Group 7 for de-
tailed removal procedure.
(3) Raise vehicle See Hoisting, Group 0.
(4) Remove vehicle's wiring harness connector (if
applicable to vehicle being serviced) from the power
steering pressure switch (Fig. 11).
(5) Put oil drain pan under vehicle to catch power
steering fluid. Remove hose clamp and low pressure
fluid hose from power steering pump (Fig. 12). (6) Remove hose clamp and hose to the power steer-
ing pump, from the remote fluid reservoir (Fig. 13).
Drain off excess power steering fluid from hoses.
(7) Remove the power steering, fluid pressure line
(Fig. 12) from the power steering pump. Drain excess
power steering fluid from tube. (8) Remove right front wheel and tire from vehicle.
This will aid in access to the power steering pump
mounting bolts. (9) Remove the 3 bolts holding the power steering
pump to the generator, power steering and belt ten-
sioner mounting bracket (Fig. 14). (10) Remove nut and bolt holding the engine block,
to power steering pump support strut. Remove strut
from engine and power steering pump (Fig. 14) Lay
the power steering pump assembly down on top
of the steering gear. It will be removed later from
the top. (11) Remove nut which holds serpentine drive belt
tensioner to its mounting bracket (Fig. 15). Remove
tensioner assembly from bracket.
Fig. 10 Serpentine Drive Belt Routing
Fig. 11 Power Steering Pressure Switch Location 3.3 & 3.8L
Fig. 12 Power Steering Hose Routing 3.3 & 3.8L
Fig. 13 Power Steering Remote Fluid Reservoir And Tube
19 - 16 STEERING Ä

(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 generator bracket. Remove the
bolt attaching the tube/hose assemblies to the power
steering pump bracket (Fig. 17). Then remove the
fluid reservoir and tube/hose as an assembly from ve-
hicle. (15) Remove the engine wiring harness routing
clip from the generator bracket. (16) Loosen but DO NOT REMOVE the bolt (Fig.
18) holding the engine bracket assembly to the en-
gine support assembly. (17) Remove upper generator to generator bracket
mounting bolt (Fig. 19). Rotate the generator assem-
bly back toward the dash panel. (18) Remove the 4 bolts holding the generator
bracket to the engine and intake manifold (Fig. 19).
Remove generator bracket from engine. (17) Remove the generator assembly, to lower gen-
erator bracket bolt (Fig. 19). Without removing wir-
ing harness from generator. Remove generator from
bracket and lay generator on top of intake manifold. (18) Remove the power steering pump out through
the top, in the area between engine and dash panel
where the generator was mounted. (19) Transfer the required parts from the removed
power steering pump, to the replacement power
steering pump.
Fig. 14 Power Steering Pump Mounting 3.3 & 3.8 ltr.
Fig. 15 Serpentine Belt Tensioner
Fig. 16 Bracket Support Strut
Fig. 17 Power Steering Fluid Reservoir Mounting
Ä STEERING 19 - 17

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

(18) Lower vehicle.
(19) Install the serpentine drive belt. Refer to (Fig.
10) for correct serpentine belt routing. See Cooling,
Group 7 for detailed installation procedure.
CAUTION: Do not use automatic transmission fluid
in power steering system. Only use Mopar T, Power
Steering Fluid, or equivalent.
(20) Fill power steering pump reservoir to correct
fluid level. (21) Connect the negative battery cable on the
negative battery post. (22) 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.
TURBO III
REMOVE
(1) Disconnect the battery (-) negative cable from
the battery and isolate cable. (2) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering
fluid. (3) Remove the right front underhood splash shield
for access to the serpentine belt tensioner. (4) Release the tension on the serpentine drive belt
tensioner and remove drive belt from power steering
pump pulley (Fig. 20). Drive belt does not have to be
fully removed from engine.
(5) Remove the power steering fluid return hose at
the steering gear metal tube. Let power steering
fluid drain from the hose and power steering pump
into drain pan. (6) Remove the high pressure fluid line banjo bolt
fitting from the power steering pump. Remove high
pressure power steering fluid line from the power
steering pump. (7) Remove the lower power steering pump to
bracket mounting nut and fluid hose routing clip. Re-
move the 2 bolts and the stud attaching the power
steering pump to its mounting bracket (Fig. 21).
(8) Lower vehicle.
(9) Remove the wiring harness electrical connector
from the H-valve on the air conditioning fluid lines. (10) Remove the power steering pump from the ve-
hicle out through the area between the cylinder head
and the dash panel (Fig. 22).
(11) Transfer the required components from the
failed power steering pump to the replacement power
steering pump. See the appropriate area of this ser-
vice manual section for the component replacement
procedures.
Fig. 20 Turbo III Accessory Drive Belt Routing
Fig. 21 Power Steering Pump Mounting
Fig. 22 Power Steering Pump Removal From Vehicle
Ä STEERING 19 - 19

INSTALL (1) Install the power steering pump back into the
vehicle in the reverse order of removal, between cyl-
inder head and dash panel (Fig. 20). (2) Install the wiring harness connector back on
the H-valve located on the air conditioning fluid
lines (Fig. 20). (3) Raise vehicle See Hoisting, Group 0.
(4) Install the power steering pump on its mount-
ing bracket, and the hose locator bracket. Install the
bolt/stud and 2 bolts attaching the power steering
pump to its mounting bracket, and the bolts attach-
ing the hose locator bracket (Fig. 19). Torque all fas-
teners to 31 N Im (280 in. lbs.).
(5) Install the power steering fluid pressure hose,
banjo bolt and seal washer onto power steering pump
(Fig. 4). Pressure hose is to be installed so it is
routed to the left of the hose locator bracket (Fig.
19). Torque the banjo bolt to 31 N Im (275 in. lbs.).
Inspect the O-rings on the banjo bolt to ensure
they are not damaged and located correctly. (6) Install the low pressure fluid return hose from
the power steering pump back on the steel tube on
the steering gear (Fig. 4). Install hose clamp, be sure
the hose clamp is installed past the retaining bead
the steel tube. Install the hose routing clip on the
power steering pump bolt/stud, install clip retaining
nut and tighten. (7) Install the serpentine accessory drive belt (Fig.
18). Be sure the belt is correctly installed and
aligned on all pulleys before starting engine. (8) Install the right front underhood splash shield.
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. (10) Connect the negative battery cable on the
negative battery post. (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.
POWER STEERING PUMP PULLEY SERVICE
SAGINAW VANE SUBMERGED PUMP
REMOVE
(1) Remove the pulley with Puller C-4333 (C-4068)
(Fig. 1).
CAUTION: Do not hammer on power steering pump
pulley. This will damage the pulley and the power
steering pump. (2) Replace pulley if bent, cracked, or loose.
INSTALLATION
(1) Install the pulley with Installer C-4063 (Fig.2).
Do not use the tool adapters.
(2) Ensure that the tool and the pulley remain
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft. (3) Force pulley flush with the end of the shaft.
Fig. 1 Pulley Removal (Typical)
Fig. 2 Pulley Installation (Typical)
19 - 20 STEERING Ä

With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0mm (0.040 in.). Be careful
that pulley does not contact mounting bolts.
SAGINAW T/C STYLE PUMP
REMOVE
(1) Mount power steering pump assembly in a vise
using one of the pump mounting bosses (Fig. 3). Do not
clamp the body of the power steering pump in vise.
Do not press or hammer on the shaft of the
power steering pump in an attempt to remove
the pulley. This will damage the internal compo-
nents of the power steering pump. (2) Remove the power steering pump pulley from the
power steering pump shaft using Puller, Special Tool
C-4333 (Fig. 4).
INSTALL
Do not press or hammer on the shaft of the
power steering pump in an attempt to install the
pulley. This will damage the internal components
of the power steering pump. (1) Place the power steering pump pulley on the end
of the power steering pump shaft. Make sure the pulley
is installed squarely on the end of the shaft (Fig. 5).
CAUTION: When installing the pulley on the Saginaw
T/C style power steering pump. The spacer that is
provided with either the replacement power steering
pump or pulley MUST be used when the pulley is in- stalled on the pump. The spacer provides for the cor-
rect pulley location on the power steering pump to
provide correct accessory drive belt alignment. The
alignment is critical in controlling accessory drive belt
noise. It also prevents the pulley from contacting the
power steering pump when it is installed, causing
power steering pump or pulley damage.
(2) Install the spacer provided with the replacement
power steering pump or power steering pulley into the
hub of the power steering pump pulley (Fig. 5).
(3) Insert the Pulley Installer, Special Tool C-4063,
(without adapters) through hole in spacer. Then
thread it into the end of the power steering pump
shaft (Fig. 6). Tighten the installer into shaft.
Fig. 4 Removing Power Steering Pump Pulley
Fig. 5 Pulley And Spacer Installed On Pump
Fig. 3 Power Steering Pump Mounted In Vise
Ä STEERING 19 - 21

(4) Hold the Pulley Installer with one wrench so it
will not rotate. Turn hex (Fig. 6) down threaded rod
of installer pushing the pulley onto the shaft of the
power steering pump (Fig. 6). Ensure that the tool
and the pulley remain aligned with the pump shaft
so pulley does not become cocked on shaft.
(5) Continue to push pulley onto shaft of power
steering pump until Pulley Installer, Special Tool
C-4063 will no longer turn. This will ensure the
spacer provided is fully seated against the front of
the power steering pump shaft (Fig. 7). (6) Remove the Pulley Installer, Special Tool
C-4063 from the shaft of the power steering pump.
Remove the supplied spacer from the hub of the
power steering pump pulley and discard.
POWER STEERING PUMP FLUID RESERVOIRS
VANE SUBMERGED PUMP (HAM CAN)
REMOVE
Discard all O-ring seals during disassembly,
they are not re-usable. (1) Remove the filler cap and drain the fluid from
reservoir before removing parts. (2) Remove mounting studs and pressure fitting
(Fig. 1). Rock reservoir by hand or use a soft face
mallet to remove. (3) Remove O-ring seals from housing and reser-
voir (Fig.1). (4) Remove flow control valve and spring from
housing.
INSTALL
Clean all parts before installation. Lubricate
new O-ring seals with Mopar tPower Steering
Fluid or equivalent. (1) Install flow control valve and spring (Fig. 2).
(2) Install new O-ring seals in housing (Fig.1). In-
stall the pump housing assembly into the fluid reser-
voir. Tighten mounting studs to 48 N Im (35 ft. lbs.)
torque. (3) Install fitting in flow control valve bore. Tighten
the fitting to 75 N Im (55 ft. lbs.) torque.
SAGINAW T/C STYLE PUMP WITH INTEGRAL
RESERVOIR
REMOVAL
Discard all O-ring seals during disassembly,
they are not re-usable. (1) Remove pump and clean exterior of pump with
solvent. (2) Remove the filler cap and drain the fluid from
reservoir. (3) Clamp the front hub of the pump in a soft jaw
vice. (4) Pry up tab and slide the retaining clip off (Fig. 3).
(5) Remove fluid reservoir from pump body. Remove
and discard O-ring seal (Fig. 4).
INSTALLATION
(1) Lubricate new O-ring Seal with Mopar Power
Steering Fluid or equivalent. (2) Install seal in housing (Fig. 4).
(3) Install reservoir onto housing (Fig. 4).
Fig. 6 Installing Power Steering Pump Pulley
Fig. 7 Power Steering Pump Pulley Installed
19 - 22 STEERING Ä

(4) Slide and tap in reservoir retainer clips until
tab locks to housing (Fig. 4). (5) Install pump. Refill reservoir with Mopar
Power Steering Fluid or equivalent.
FLOW CONTROL VALVE FITTING O-RING SEAL
REMOVAL
(1) Remove pressure hose from pump fitting. Re-
move pump and pulley if necessary. (2) Remove fitting from pump housing (Fig. 5).
Pre-
vent flow control valve and spring from sliding
out of housing bore. (3) Remove and discard O-ring seal (Fig. 5).
INSTALLATION
(1) If necessary, clean and install flow control valve
and spring in pump housing bore (Fig. 5). Be sure the
hex nut end of the valve is facing the in toward
the pump. (2) Install O-ring seal onto fitting (Fig. 5).
(3) Install fitting in pump housing and tighten to 75
N Im (55 ft. lbs.)
(4) Install pump and pulley if necessary. Install
pressure hose to fitting.
Fig. 1 Pump and Reservoir
Fig. 2 Flow Control Valve/Spring Installation
Fig. 3 Remove Reservoir Clips (Typical)
Ä STEERING 19 - 23