Power Steering System Noise and/or Leak Diagnosis

This bulletin is being revised to update model year information, diagnostic information, parts information, and claim information. Please discard Saturn Bulletin 02-T-46, Corporate Bulletin Number 02-02-32-009 (Section 02 -- Steering).

The purpose of this bulletin is to provide general diagnostic information about power steering noise and/or leak diagnosis on Saturn L-Series and S-Series vehicles equipped with hydraulic power steering.

Refer to the information contained in this bulletin to aid in diagnosing and repairing power steering noise and/or leaks. Once a noise and/or leak is found, refer to the appropriate section of the Chassis Service Manual for repair procedure.

MOAN, GROAN, AND GROWL NOISES

These types of noises may be caused by insufficient or excessive power steering pump flow or system pressure, incorrect power steering fluid level or poor fluid condition or contamination.

To diagnose and correct Power Steering System Noises, reference the Power Steering System Test Procedure in the corresponding Service Manual. 1991-2002 S-Series (SI Document ID #874502), 2000-2002 L-Series (SI Document ID #895490), 2003-2005 L-Series (SI Document ID #1204228).

Additionally, these different noises may be caused by air in the power steering fluid. The air may be a result of an external leak which will allow air to enter the fluid during periods of high suction from a low fluid level in the reservoir. If the fluid level is at or below the add line with the engine idling, inspect for an external leak. Possible leak areas are:

The system may also have a leak that allows air to be drawn in. This can occur anywhere on the return side of the system where pressures are low. In this case, the reservoir will be full but the fluid will still contain air.

If a leak is suspected, perform the following:

Important: The presence of dust on the power steering gear does not automatically indicate a leak. Some fluid may drip onto the gear during the assembly process and will attract dust over time. A leak in the power steering gear or hoses should be suspected only if there are signs of recent fluid flow, i.e. fresh fluid without dust accumulation or evidence of a trail of fluid through a dusty area.

Visually inspect pump, hoses, and gear for signs of leakage. If a leak is located refer to the appropriate Chassis Service Manual for repair procedure.

In addition to visual inspection, the following diagnostics may help to locate the source of either type of leak.

Vacuum Test

Use J35555 (SA9180NE) Metal Mityvac® (vacuum tester), or equivalent, and J45727 Power Steering Bleeder Adapter (power steering stopper) (see illustration) to vacuum test the system.

Notice: To prevent damage to the vacuum pump seals by the power steering fluid, always use a fluid collector between the vacuum pump and power steering pump reservoir.

1. Verify that power steering fluid reservoir is at the FULL mark. If necessary, add fluid before beginning test.
2. Attach vacuum tester (J35555 or equivalent) to the power steering stopper (J45727) with supplied hose.
3. Remove power steering reservoir cap.
4. Place power steering stopper (J45727) on top of reservoir.
5. Draw maximum of 68 kPa (10 psi, 20 in. Hg) vacuum on the system.
6. Wait 5 minutes.
7. Vacuum should not drop by more than 7-10 kPa (1-1.5 psi, 2-3 in. Hg).

Important: This test does not indicate the location of the leak and further component checks need to be performed to isolate the leak.

8. If vacuum does drop by more than 7-10 kPa (1-1.5 psi, 2-3 in. Hg), then a leak is present.

Dye Test (Used to locate leak)

If the vacuum test indicates that a leak is present, perform the following:

Important: On L-Series vehicles with 2.2L four-cylinder (L61) engines with a direct drive power steering pump, check for presence of dye in the engine oil by removing the dipstick and inspecting with a black light. All 2000 model year L-Series 2.2L four-cylinder (L61) engines had dye installed at the time of manufacture.

Important: If the engine has had dye installed, the oil splash from the cam will make it impossible to tell if there is a leak from the power steering pump shaft seal. Traces of dye can last well over 32,200 km (20,000 miles) even with regular oil changes. Do not perform dye test if engine has dye installed.

1. Add one cap full of Saturn automatic transaxle dye, P/N 21007650 (in Canada, P/N 10953490), or equivalent, to the power steering reservoir. Allow dye to circulate throughout the system by turning the steering wheel side to side as the engine idles for 2 minutes.
2. Use the black light to check for leaks in the locations listed previously in this bulletin. (The direct drive pump on L-Series vehicles with 2.2L four-cylinder (L61) engines must be removed to check for a leaking shaft seal since oil leaking from the pump will drain into the engine oil pan.)

Once a leak is found, refer to the appropriate section of the Chassis Service Manual for repair procedure.

When the leak is repaired and system is bled per the Service Manual, or if no leak was present, but the system still has a moan or groan noise, perform the following:

Caution: Make sure vehicle is properly supported and squarely positioned on the hoist. To avoid any vehicle damage, serious personal injury or death when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which components are being removed. This will reduce the possibility of the vehicle falling off the hoist.

Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack.

Notice: Perform the following steps before starting any vehicle lifting or jacking procedure:

•	Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.

•	The lifting or jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents.

•	The lifting or jacking equipment must meet the operational standards of the lifting or jacking equipment's manufacturer.

•	Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.

•	Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting or jacking equipment to contact any other vehicle components.

Failure to perform the previous steps could result in damage to the lifting or jacking equipment, the vehicle, and/or the vehicle's contents.

Important: Place jackstands ONLY under strong and stable vehicle structures.

1. Position vehicle on hoist and raise so that the wheels are off the ground.
2. Make certain the fluid level is at or above the COLD line on the dipstick.
3. Turn engine OFF, but make sure steering column remains unlocked.
4. Use vacuum tester J35555 or equivalent and power steering stopper J45727 with the separator cup installed between the vacuum tester and stopper to pull 85 kPa (12 psi, 25 in Hg) vacuum on the system.
5. Turn the steering wheel lock to lock 10 times. Do this slowly so that any air in the system has time to separate from the fluid.
6. After 10 turns lock to lock, check vacuum pressure. If it has dropped, increase vacuum to 85 kPa (12 psi, 25 in Hg).
7. Start engine and allow to idle.
8. Turn steering wheel another 10 times lock to lock.

Important: This system is designed to build pressure as the fluid warms up. This pressure helps to keep the pump quiet. Before reevaluating the system for noise, let it cool.

9. Remove vacuum adapter, check fluid level and adjust if necessary, then install cap.

POP OR CRUNCH NOISE FROM STEERING WHEEL OR STEERING COLUMN

Possible causes for pop or crunch noises that can be felt in the steering wheel or heard coming from the area of the steering column are:

Diagnostic Procedure

1. Verify customer concern.
2. Use Chassis Ears J39570 (SA9217NE), or equivalent, or visually inspect to isolate location of noise.
3. Turn the steering wheel while holding onto the intermediate shaft to determine if the shaft is causing the noise.
4. Refer to appropriate Service Manual to disarm the SIR system before disconnecting the intermediate shaft. Remove the intermediate shaft and extend and contract its length to redistribute the lubrication.

Notice: Turning the steering wheel too far with the intermediate shaft disconnected will result in damage to the SIR roll coil. While intermediate shaft is removed, carefully turn the steering wheel 180° (½ turn) each way and check for noise. It may be helpful to restrain the lower end of the steering column and check for noise while applying torque to the steering wheel.

5. Reinstall the intermediate shaft into the vehicle and again feel and listen while turning the steering wheel.

* One cap full of Saturn Automatic Transmission Dye is needed for this procedure. One bottle can service approximately 20 vehicles.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for E9856 (Fluid, Power Steering Flush/Bleed) and/or E9040 (Pump Assembly, Power Steering - R & R).