Procedure

1. Siphon the power steering fluid from the power steering reservoir.

2. Remove the accessory drive belt.

3. Remove the power steering pressure hose from the power steering pump.

4. Remove the power steering return line. Discard the power steering return line.

5. Remove the power steering pressure line from the steering gear. Discard the power steering pressure line.

6. Attach the new P/S return line to the reservoir nipple and secure with a spring clamp.








7. Install the new power steering pressure line observing the appropriate routing as shown in the figure.

8. Loosely install the new P/S pressure hose to the pump discharge fitting.

9. Secure the clip on the return line to the engine as shown and install with an M12 x 1.75 x 20 bolt (P/N 10164181). Tighten clip bolt to 14 N.m (10 lb ft).

10. Trim the rubber return hose attached to the P/S cooler to a total length of 310 mm (12-1/4 in).

11. Tighten the pressure line fitting at pump to 27 N.m (20 lb ft).

12. Carefully position the new pressure hose, forming a hose loop (1) as shown. Following this routing should result in an exhaust manifold heat shield to hose clearance of at least 43 mm (1.75 in).

Notice:
The power steering pressure hose to the exhaust manifold clearance must be at least 43 mm (1.75 in) minimum or damage to the new power steering hose will result. If clearance is insufficient, the hose routing or the part number is incorrect. Be sure to follow the illustrated routing to avoid a build-up of torque in the P/S pressure hose assembly.

13. Loosely attach the pressure pipe to the steering gear inlet.

14. Install the pressure pipe to the steering gear housing clip.

15. Tighten the pressure pipe fitting at the steering gear to 27 N.m (20 lb ft).

16. Attach the shortened hose to the return pipe and secure with a spring clamp.

17. Inspect installation and verify clearance between the pressure hose and the exhaust manifold, bulkhead, and other adjacent components. If necessary, loosen the fittings, reposition the hoses and tighten the fittings to the torque values outlined above.

18. Fill the power steering reservoir with new power steering fluid. Bleed the system. Refer to the Bleeding Power Steering System in the Power Steering sub-section of the 1999 W Car Service Manual.

19. Visually check all the fittings for leaks.