For 1990-2009 cars

## Power Steering Pump Replacement ZF

### Removal Procedure

Note: The front axle body remains fitted. The electro-hydraulic supply unit of ZF is removed from above with the holder.

1. Pump the hydraulic fluid out of the electro-hydraulic supply unit.
2. Disconnect the wiring harness from the electro-hydraulic supply unit.

2.1. | Unlatch and disconnect the wiring harness plug (3).

2.2. | Release the primary lock (1) from the wiring harness plug.

2.3. | Compress the secondary lock and separate the wiring harness plug (2).

3. Remove the lower engine compartment cover.

Remove the 10 bolts.

Note: Oil will run out, use a drain pan.

4. Remove the supply and return line from the electro-hydraulic supply unit.

Remove the bolt (1).

5. Remove the electro-hydraulic supply unit with bracket from the front axle body.

Remove the 3 nuts.

### Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

Note: Note the steering wiring harness.

1. Place the electro-hydraulic supply unit with bracket on the front axle body.

Install the electro-hydraulic supply unit to front axle body.

Tighten
Tighten the 3 nuts to 22 N·m (16 lb ft).

Note: Do not attach the bracket for electro-hydraulic supply unit at this time.

2. Install the pressure and return lines to the electro-hydraulic supply unit with the new seal rings.

Tighten
Tighten the bolt (1) 16 N·m (12 lb ft).

3. Connect the wiring harness with the electro-hydraulic supply unit.

Connect and lock the 2 wiring harness plugs.

4. Remove the lower engine compartment cover.

Tighten
Tighten the 10 bolts (1).

5. Add special fluid to the oil tank up to the "MAX" mark (1) on the oil dipstick.
6. Place the cover on oil tank and close.
7. Bleed the power steering system. Refer to Power Steering System Bleeding.
8. For programming procedures, refer to Control Module References.

## Power Steering Pump Replacement TRW

Note: The front frame remains fitted. The electro-hydraulic supply unit of TRW is removed from above without holder.

### Removal Procedure

1. Remove the battery. Refer to Battery Replacement.
2. Remove the battery tray. Refer to Battery Tray Replacement.

Note: The cooling system remains sealed.

3. Reposition the surge tank. Refer to Radiator Surge Tank Replacement.

Disconnect the wiring harness plug.

4. Disconnect the steering wiring harness.

• | Disconnect the cover from the positive distribution.

• | Remove the wiring harness from the fixing (1).

• | Disconnect the wiring harness plug for steering (2).

• | Disconnect the ground cable (3) for steering wiring harness from ground pole terminal.

• | Expose wiring harness for steering underneath. Note wiring route.

- | Remove the cable ties.

- | Release the wiring harness from the holder.

5. Remove the air cleaner housing with the air intake hose.
6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
7. Remove the bleed hose from the tank bleed valve.

• | Disconnect the quick-acting closure.

• | Release from the holder.

8. Remove the right engine splash shield.
9. Disconnect the wiring harness for the steering from the front frame.

Note: Oil runs out, use a drain pan.

10. Remove the return (1) and supply line (2) from the electro-hydraulic supply unit.
11. Remove the electro-hydraulic supply unit from the holder.

Remove the 3 nuts (1-3) from the holder.

Note: Remove the electro-hydraulic supply unit upwards.

12. Remove the electro-hydraulic supply unit from the holder.

### Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

Note: Note steering wiring harness.

1. Insert the electro-hydraulic supply unit in the bracket.

Attach the electro-hydraulic supply unit to the bracket.

Tighten
Tighten the 3 nuts to 7 N·m (62 lb in).

Note: Ensure the wiring is routed properly.

2. Position the wiring harness and attach to the front frame.
3. Tighten the retaining nut.

Tighten
Tighten the nut to 30 N·m (22 lb ft).

4. Install the right engine splash shield.
5. Connect the steering wiring harness.

• | Position the steering wiring harness.

- | Attach the cable ties.

- | Clip the wiring harness into the brackets.

• | Detach the cover from the positive distribution.

• | Attach the wiring harness to fixing (1).

• | Connect the wiring harness plug for steering (2).

• | Attach the ground cable (3) for the steering wiring harness to the ground pole terminal.

6. Attach the coolant surge tank to the holder.
7. Install the battery tray. Refer to Battery Tray Replacement.

Note: Do not connect the battery ground at this point.

8. Install the battery. Refer to Battery Replacement.
9. Fit the bleed hose to the tank bleed valve.

• | Connect the quick-acting closure.

• | Clip into the bracket.

10. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
11. Connect the battery ground terminal.

Tighten
Tighten to 5 N·m (44 lb in).

12. Fill the power steering. Refer to Checking and Adding Power Steering Fluid.
13. Charge and bleed the hydraulic system. Refer to Power Steering System Bleeding.
14. For programming procedures, refer to Control Module References.