2000-01 STEERING Power Rack & Pinion - Saturn L Series

2000-01 STEERING
Power Rack & Pinion - Saturn "L" Series
DESCRIPTION & OPERATION
The major components of the power steering system are the steering wheel, steering column and shaft assembly,
intermediate shaft, power steering gear, tie rods, steering knuckles, power steering pump and hoses.
When steering wheel is turned, steering gear input shaft/pinion gear teeth mesh with horizontal rack teeth to
move rack left or right. Rack is connected to steering knuckles by inner tie rods and tie rod ends.
Engine mounted belt driven power steering pump supplies pressurized fluid to the steering gear input shaft.
Shaft contains a spool valve that directs fluid to either side of the rack piston, depending on turning direction.
Fluid pressure reduces the effort required to turn the steering wheel.
SYSTEM TESTS
PRESSURE & FLOW RATE TEST
1. Disconnect high pressure line at steering gear and install Power Steering System Tester (SA9134C), or
equivalent. Open gate valve on power steering system tester. Run engine until it has reached normal
operating temperature. Replace any power steering fluid lost during power steering tester installation.
Bleed system if necessary. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
2. With engine idling, record power steering pressure and flow rate. If pressure is greater than 150 psi (10.5
kg/cm2 ), stop engine and check for restricted power steering hose lines.
3. Partially close valve until pressure is 700 psi (49 kg/cm2 ). Record power steering fluid pressure and flow
rate. If flow rate observed drops 1 gallon (3.8L) or more, replace power steering pump.
4. Completely close valve for a few seconds, and then open it. Repeat 3 times, recording highest pressure
obtained each time valve is closed. If all 3 readings are not within 50 psi (3.5 kg/cm2 ) of each other and
at 1300-1400 psi (91.4-98.4 kg/cm2 for L61 engine, or 1400-1500 psi (98.4-105.5 kg/cm2 ) for L81
engine, replace flow control valve.
5. With gate valve open, increase engine speed to 1600 RPM, and record power steering fluid pressure and
CAUTION: To prevent power steering pump damage during pump pressure
testing, open valve on tester before starting engine. During testing,
DO NOT turn steering wheel unless specified in procedure.
NOTE: Turning steering wheel while performing test will cause inaccurate results.
CAUTION: Pump will be damaged if tester valve is held closed for more than 5
seconds.
2001 Saturn L300
2000-01 STEERING Power Rack & Pinion - Saturn "L" Series
2001 Saturn L300
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Monday, May 09, 2011 11:36:40 AM Page 1 © 2006 Mitchell Repair Information Company, LLC.
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flow rate. If difference between this flow rate and that obtained in step 2 is less than one gallon (3.8L) per
minute, go to next step. If difference between flow rates is greater than one gallon (3.8L) per minute,
replace flow control valve.
6. Turn steering wheel from stop to stop, recording pressure and flow rate at each stop. DO NOT hold
steering wheel at stops for more than 5 seconds. If flow rate at either stop is greater than one gallon (3.8L)
per minute, steering gear is leaking internally. Replace steering gear. Remove tester. Fill and bleed
system. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
LUBRICATION
FLUID TYPE
Use power steering fluid meeting GM specification 9985010.
CAPACITY
Power steering pump and system capacities are not provided by manufacturer.
FLUID LEVEL CHECK
Maintain fluid level between FULL COLD and FULL HOT marks on dipstick or fluid reservoir.
HYDRAULIC SYSTEM BLEEDING
1. Turn ignition off. Raise and support front of vehicle with wheels off ground. Turn wheels fully to left.
Check fluid level. If necessary, add power steering fluid to FULL mark on fluid level indicator. Turn
wheels from side to side several times, but DO NOT touch steering stops. Add fluid, if necessary, to
maintain level at FULL mark.
2. Start engine. With engine idling, check fluid, and add as necessary. Return wheels to center position.
Lower vehicle. Continue to run engine for 2-3 minutes to bring fluid to operating temperature.
3. Road test vehicle. Check for leaks. Ensure fluid level is at FULL mark when fluid stabilizes at operating
temperature.
ADJUSTMENTS
POWER STEERING PUMP BELT
Power steering pump belt adjustment information not provided by manufacturer.
RACK BEARING PRELOAD
NOTE: If air was allowed into hydraulic system during servicing, bleed system. Aerated
fluid, which is Light Tan in color, results in poor steering performance and
causes pump damage.
2001 Saturn L300
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1. Raise and support vehicle. Turn front wheels to straight-ahead position. Loosen steering gear adjuster
plug lock nut. See Fig. 1 . Turn adjuster plug clockwise until it bottoms in housing, and then tighten plug
to specification. See TORQUE SPECIFICATIONS . Back off adjuster plug 50 +/-5 degrees (slightly
less than one flat of nut). See Fig. 1 .
2. While holding adjuster plug stationary, tighten adjuster plug lock nut to specification with crows foot
wrench. Test drive vehicle, ensuring steering wheel returns to center after turning.
Fig. 1: Adjusting Rack Bearing Preload
Courtesy of GENERAL MOTORS CORP.
REMOVAL & INSTALLATION
OUTER TIE ROD
Removal
1. Raise and support vehicle on hoist. Support opposite end of vehicle from which components will be
removed. Remove wheel assembly. Loosen tie rod jam (adjuster) nut. Remove and discard tie rod end
nut.
2. Using Tie Rod Separator (SA91100C), or equivalent, separate outer tie rod from steering knuckle. DO
NOT separate tie rod end using a wedge-type separator. Seal may be damaged. Unthread tie rods from
each other.
Installation
WARNING: If wheels are removed, remove rust and corrosion from mounting
surfaces of wheel and brake rotor before installing wheels. Failure to do
so can cause wheel lug nuts to loosen in service.
2001 Saturn L300
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1. Thoroughly clean threads on tie rod end stud. Thread tie rods together. Seat tie rod into steering knuckle
using Steering Linkage Installer (J44015), or equivalent, and tighten installer to specified torque. See
TORQUE SPECIFICATIONS . Remove linkage installer.
2. Install NEW tie rod end-to-knuckle nut, and tighten to specification. Finger tighten jam nut. To complete
installation, reverse remainder of removal procedure. Tighten all fasteners to specification. See
TORQUE SPECIFICATIONS . Check front wheel toe. See appropriate SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
RACK & PINION BOOTS
Removal
Remove outer tie rod. See OUTER TIE ROD . Remove jam nut from inner tie rod. Remove outer boot clamp.
Remove inner boot clamp with cutters, and discard clamp. Remove boot from steering gear.
Installation
1. Install NEW clamp on inner end of boot. Apply service kit grease to areas on steering gear and inner tie
rod where boot will make contact when installed. Slide steering gear boot onto rod assembly until large
end of boot is seated into steering gear housing groove.
2. Crimp inner end of boot clamp using Clamp Pliers (SA9164C). Install and crimp outer boot clamp. Install
jam nut onto inner tie rod. To complete installation, reverse remainder of removal procedure. Tighten all
fasteners to specification. See TORQUE SPECIFICATIONS .
INNER TIE ROD
Removal
1. Loosen jam nut. Remove steering gear. See STEERING GEAR . Unthread tie rods. Remove jam nut.
Remove steering gear boot. See RACK & PINION BOOTS . Slide shock damper off inner tie rod,
toward steering gear.
2. If removing right inner tie rod, remove left boot for access to rack teeth. Place a shop towel over rack
teeth, and position Inner Tie Rod Wrench (SA9209C), or equivalent, over shop towel to rigidly hold and
support rack. See Fig. 2 . While holding rack with wrench, remove inner tie rod with wrench, and remove
from gear.
Installation
1. Remove old Loctite(R) from rack and inner tie rod threads. Apply Loctite 262(R) , or equivalent, to inner
tie rod threads. Screw inner tie rod onto rack threads. Place towel over rack teeth and position Inner Tie
Rod Wrench (SA9209C) over shop towel to rigidly hold and support rack. See Fig. 2 .
2. While holding rack with wrench, tighten inner tie rod to specification. See TORQUE
CAUTION: If rack is not prevented from rotating when loosening or tightening
inner tie rod, steering gear will be damaged.
2001 Saturn L300
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SPECIFICATIONS . Slide shock damper up against inner tie rod. Apply grease to areas on steering gear
and inner tie rod where boot will make contact when installed. Install steering gear boot and clamps.
Ensure boot is not twisted or puckered.
3. Thread jam nut onto inner tie rod. Thread outer tie rod end onto inner tie rod. To complete installation,
reverse remainder of removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Check front wheel toe. See appropriate SPECIFICATIONS & PROCEDURES
article in WHEEL ALIGNMENT.
Fig. 2: Removing Inner Tie Rod From Rack
POWER STEERING PUMP
Removal (L61)
Remove power steering pump reservoir fill cap. Place approved drain container under hose at steering gear.
Remove power steering hoses from steering gear, and allow system to drain. Remove power steering hoses from
power steering pump. Remove power steering pump-to-cylinder head fasteners, and remove pump from vehicle.
Installation
To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS . Fill and bleed hydraulic system. See HYDRAULIC SYSTEM BLEEDING under
LUBRICATION.
Removal (L81)
NOTE: DO NOT rotate steering wheel when hoses are removed, or power steering fluid
will be forced out of gear.
2001 Saturn L300
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1. Disconnect manifold air flow electrical connector. Unsnap EVAP purge valve assembly, and secure aside
from air cleaner assembly. To remove air cleaner lid, loosen hose clamp at throttle body. Slide off flexible
manifold air flow hose-to-throttle body hose. Unclamp lid, and remove lid, manifold air flow sensor, and
hose as assembly. Remove air cleaner from box. Remove air box mount bolt, and remove air box.
2. Remove power steering pump pulley bolts. Relieve spring tension from accessory drive belt, and remove
belt from power steering pump pulley. Remove pulley. Place approved drain container under power
steering pump. Remove power steering pump pressure and hoses, and allow system to drain. Remove
power steering pump bracket fasteners, and remove pump from vehicle.
Installation
1. Position power steering pump into vehicle. Finger-tighten all pump-to-bracket bolts, then tighten to
specification. See TORQUE SPECIFICATIONS . Inspect "O" ring on pressure hose, and replace if
necessary. Install pressure and return hoses, and tighten to specification. Install pump pulley, and finger-
tighten bolts. Install accessory drive belt. Tighten pulley bolts to specification.
2. To complete installation, reverse remainder of removal procedure. Tighten all fasteners to specification.
See TORQUE SPECIFICATIONS . Fill and bleed hydraulic system. See HYDRAULIC SYSTEM
BLEEDING under LUBRICATION.
PUMP DRIVE SHAFT SEAL
Removal
Remove power steering pump. See POWER STEERING PUMP . On models with L81 engines, remove pump
pulley hub from pump using Power Steering Hub Puller (SA9218NE), or equivalent. On all models, wrap thin
piece of shim stock around seal area of shaft to protect shaft. Using a small chisel, pry seal from pump housing.
Installation
Lubricate NEW shaft seal with power steering fluid. Install seal into pump housing using a suitable socket. On
models equipped with L81 engines, install pump pulley hub using Power Steering Hub Replacer (SA9162C-2),
or equivalent. For both L61 and L81 engine types, install pump. Fill and bleed hydraulic system. See
HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
STEERING GEAR
Removal
1. From inside of vehicle, remove intermediate shaft-to-steering gear pinch bolt, and disconnect shaft. On
vehicles equipped with L81 engines, remove rear exhaust manifold pipe heat shield. For both engine
types, Remove rear transaxle mount through-bolt and transaxle mount-to-frame bolt.
2. Place approved drain container under pressure and return hose at steering gear. Remove hose from
steering gear, and allow system to drain. Raise and support vehicle on hoist. Support opposite end of
NOTE: Rotating steering wheel while disconnected from steering gear may cause
damage to SIR coil.
2001 Saturn L300
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vehicle from which components will be removed. Remove front wheels.
3. Remove right front lower splash shield. Disconnect O2 sensor electrical connection. On vehicles
equipped with L61 engines, remove O2 sensor clamp-to-underbody nut. On vehicles equipped with L81
engines, remove O2 sensor from exhaust manifold pipe. On vehicles equipped L61 engine and manual
transmission, and vehicles equipped with L81 engines, remove exhaust manifold pipe. For all vehicle
types, remove remaining rear transaxle mount-to-frame bolts, and remove rear transaxle mount.
4. While holding tie rod end ball stud from turning, remove tie rod end nut, and discard. Using Tie Rod
Separator (SA91100C), or equivalent, separate tie rod end from knuckle. On vehicles equipped L61
engine and manual transmission, remove cradle-to-shifter link pivot pin clip. On all vehicle types, remove
steering gear-to-frame assembly bolts. On vehicles equipped with L61 engines and automatic transaxle,
remove steering gear heat shield.
5. On all vehicle types, while holding stabilizer link ball stud, remove stabilizer bar link-to-strut assembly
nut. Remove front suspension support assemblies. Loosen remaining from-to-body attachment fasteners
until there is enough clearance to remove steering gear through driver-side wheel opening. Remove
steering gear.
Installation
1. Individually remove frame bolts and cage nuts. Install steering gear into vehicle through left wheel
opening. Using powertrain support dolly and Frame Alignment Fixture (J43628), raise frame assembly to
vehicle. Install NEW bolts and NEW cage nuts. Tighten to specification. See TORQUE
SPECIFICATIONS . Using NEW bolts and NEW cage nuts, install suspension support assembly.
Tighten nuts and bolts to specification.
2. On vehicles equipped with L61 engine and manual transaxle, install cradle-to-shifter link pivot pin clip.
For all vehicle types, install steering gear onto frame using NEW bolts and nuts, and tighten to
specification. On vehicles equipped with L61 engine and automatic transmission, install steering gear
heat shield, and tighten fasteners to specification.
3. Install and seat thoroughly cleaned tie rod end into steering knuckle using Tie Rod End Linkage Installer
(J44015), or equivalent. Tighten installer to specification. See TORQUE SPECIFICATIONS . While
holding ball stud from turning, install NEW tie rod end nut.
4. Install stabilizer bar link into strut assembly. While holding stabilizer bar link ball stud from turning,
tighten stabilizer bar link-to-strut nut. Install rear transaxle mount, and tighten mount-to-frame bolts to
specification. Install power steering hoses onto steering gear, and tighten to specification.
5. On vehicles equipped L61 engine and manual transmission, and vehicles equipped with L81 engine,
install exhaust manifold pipe onto exhaust manifold. Tighten nuts to specification. See TORQUE
SPECIFICATIONS . Tighten exhaust manifold pipe-to-exhaust pipe bolts to specification. On vehicles
equipped with L61 engine, install O2 sensor clamp onto underbody bolt, and tighten nut to specification.
Connect O2 sensor electrical connector.
6. Install wheel assemblies. Finger-tighten wheel lug nuts. Tighten lug nuts as specified in torque
specifications table. See TORQUE SPECIFICATIONS . Lower vehicle. Install remaining rear transaxle
mount through-bolt, and transaxle mount-to-frame bolt, and tighten to specification.
7. On vehicle equipped with L61 engine and automatic transaxle, install steering gear heat shield, and
tighten fasteners to specification. On vehicles equipped with L81 engines, install O2 sensor onto exhaust
manifold pipe, and install exhaust manifold pipe heat shield. Install intermediate shaft onto steering gear.
Lubricate intermediate shaft-to-steering gear pinch bolt with Loctite 242(R), or equivalent, and tighten to
2001 Saturn L300
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specification. Bleed system. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION. Check
front wheel toe. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL
ALIGNMENT.
OVERHAUL
POWER STEERING GEAR
POWER STEERING PUMP
Disassembly
1. Remove power steering pump from vehicle. See POWER STEERING PUMP under REMOVAL &
INSTALLATION. On models with L61 engines, remove power steering reservoir retaining clips from
assembly, and remove reservoir and "O" ring seal from power steering reservoir housing. On models with
L81 engines, use Power Steering Pump Hub Puller (SA9218NE), or equivalent, and remove hub.
2. For both pump types, place punch into power steering pump housing access hole, and remove retaining
ring. See Fig. 3 . If necessary, compress end cover with one end of "C" clamp on end cover, and other end
on shaft (put a piece of wood between shaft end and clamp to protect shaft).
3. Gently push drive shaft to remove end cover, "O" ring, pressure plate spring and pressure plate. See Fig.
3 . Remove drive shaft assembly consisting of shaft, rotor, vanes, pump ring, thrust plate and shaft
retaining ring. Remove large "O" ring, 2 dowel pins and shaft seal from pump housing. Remove shaft
retaining ring to disassemble shaft assembly.
NOTE: Overhaul information on power steering gear is not available from
manufacturer.
2001 Saturn L300
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Fig. 3: Exploded View Of Power Steering Pump (Typical)
Inspection
Clean all parts with power steering fluid. Replace damaged components. A wavy pattern may be present on
pump ring face. This is a normal condition for pumps with low mileage.
Reassembly
1. Lubricate new drive shaft seal with power steering fluid. Using suitable socket as driver, install NEW
drive shaft seal into power steering pump housing. See PUMP DRIVE SHAFT SEAL under
REMOVAL & INSTALLATION. Install thrust plate and power steering pump motor onto drive shaft.
Install NEW shaft retaining ring onto drive shaft. Install drive shaft, rotor, and thrust plate, as assembly,
into housing. See Fig. 3 .
2. Install pump ring dowel pins into power steering pump housing through thrust plate. Install pump ring
into housing with indentation on pump ring facing up. See Fig. 4 . Install vanes into pump rotor (vanes
can be installed in either direction).
3. Install NEW lubricated pump housing "O" ring into housing groove. Align holes in pressure plate with
dowel pins, and then install pressure plate. See Fig. 3 . Position pressure plate spring against pressure
plate (spring can be installed in either direction).
4. Install NEW lubricated "O" ring onto end cover. Lubricate outer edge of end cover. Press end cover into
NOTE: Pump will not operate if pump ring is installed with indentation on pump
ring facing downward. See Fig. 4 .
2001 Saturn L300
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housing far enough to install retaining ring. Ensure retaining ring is fully seated in groove. If necessary,
compress end cover with one end of "C" clamp on end cover, and other end on shaft (put a piece of wood
between shaft end and clamp to protect shaft).
5. On models with L61 engines, install NEW lubricated reservoir "O" ring onto reservoir, and push reservoir
straight into pump housing. Install reservoir retaining clips. On models with L81 engines, install pump
pulley hub using power steering Pump Pulley Installer (SA9162C-2), or equivalent. For both pump types,
install pump. See POWER STEERING PUMP under REMOVAL & INSTALLATION. Fill and bleed
hydraulic system. See HYDRAULIC SYSTEM BLEEDING under LUBRICATION.
Fig. 4: Installing Pump Ring (Typical)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Exhaust Manifold Pipe-To-Exhaust Manifold Nuts 22 (30)
Exhaust Manifold Pipe-To-Exhaust Pipe Bolts 15 (20)
Frame Assembly-To-Body Bolts
Step 1 66 (90)
Step 2 Tighten an
additional 45-60
degrees
2001 Saturn L300
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Inner Tie Rod-To-Gear Rack 70 (95)
Intermediate Shaft-To-Steering Gear Pinch Bolt 22 (30)
O2 Sensor-To-Exhaust Manifold Pipe (L81) 33 (45)
Pressure & Return Hose Fittings 20 (27)
Pump Pulley-To-Hub Bolt 15 (20)
Pump-To-Bracket Bolts (L81) 15 (20)
Pump-To-Cylinder Head Nuts & Bolts (L61) 18 (25)
Rear Transaxle Mount Through-Bolt 66 (90)
Rear Transaxle Mount-To-Frame Bolts 44 (60)
Stabilizer Bar Link-To-Strut 48 (65)
Steering Gear Adjuster Plug 9 (12)
Steering Gear Adjuster Plug Lock Nut 52 (70)
Steering Gear-To-Frame Nuts & Bolts
Step 1 33 (45)
Step 2 Tighten an
additional 45-60
degrees
Suspension Support-To-Body Bolts
Step 1 66 (90)
Step 2 Tighten an
additional 45-60
degrees
Tie Rod Linkage Installer 33 (45)
Tie Rod-To-Knuckle Nut 44 (60)
Wheel Lug Nuts (1) 92 (125)
INCH Lbs. (N.m)
Heat Shield-To-Exhaust Manifold Pipe Bolts (L81) 71 (8)
O2 Sensor Clip-To-Underbody Nut (L61) 35 (4)
Steering Gear Heat Shield-To-Frame Nuts & Bolts (L61) 35 (4)
(1) Install nuts finger tight. Tighten nuts to 46 ft. lbs.(63 N.m) in star pattern. Tighten nuts to final torque
of 92 ft. lbs. (125 N.m) in star pattern.
2001 Saturn L300
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2000-01 STEERING Power Rack & Pinion - Saturn L Series

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2000-01 STEERING Power Rack & Pinion - Saturn L Series