GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Engine 🢒 Engine Controls - 1.9L 🢒 Power Steering Pump Replacement

Removal Procedure
  1. Disconnect negative battery cable.
  2. Remove power steering pump reservoir fill cap.

    3. Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  3. Raise vehicle on hoist.

    4. Object Number: 862140 Size: SH
  4. Place approved drain container under power steering hoses at steering gear.
  5. Disconnect power steering hoses from the steering gear.

    6. Important: After removing power steering hoses from gear, do not rotate steering wheel since fluid will be forced out of gear.

  6. Remove power steering hoses from steering gear and allow system to drain.

    7. Object Number: 860178 Size: SH
  7. Use a box end wrench to relieve spring tension from accessory drive belt tensioner; remove belt from power steering pump pulley.

    8. Object Number: 864788 Size: SH
  8. On vehicles equipped with variable assist, disconnect EVO electrical connector.

    9. Important: It is not necessary to remove the three power steering pump bracket to engine block bolts.

  9. On DOHC (LL0) engine, loosen upper power steering pump bracket bolt at cylinder head.
    10. 9.1. Remove upper power steering pump bracket bolt at power steering pump.
    9.2. Swing bracket aside.

    Object Number: 859575 Size: SH
  10. Remove three power steering pump-to-bracket bolts only. Obtain access to bolts by rotating power steering pump pulley.

    11. Object Number: 861002 Size: SH
  11. Remove pump (with hoses) from vehicle.
  12. Remove pressure and return hoses from pump.

Installation Procedure

    Object Number: 861002 Size: SH
  1. Inspect O-ring seals on each end of the pressure hose and on the gear end of the return hose and replace if necessary. Install pressure and return hoses onto pump.

    2. Tighten
    Tighten Power Steering Hoses-to-Steering Pump 27.5 N·m (20 lbs ft).


    Object Number: 862027 Size: SH

    Important: Do not tighten any of the bolts until all bolts have been started.

  2. Position pump with hose against cylinder head and loosely install all bolts. Install the power steering pump bracket-to-cylinder head support brace bolts first on the DOHC (LL0) engine.

    3. Object Number: 864788 Size: SH
  3. Torque the three power steering pump-to-bracket bolts.

    4. Tighten
    Tighten Power Steering Pump-to-Bracket Bolt 30 N·m (22 lbs ft).

  4. On the DOHC (LL0) engine, torque the support bracket bolt to power steering pump first; then torque the upper support bracket bolt at the cylinder head.

    5. Tighten
    Tighten Power Steering Pump-to-Bracket Bolt 30 N·m (22 lbs ft).

  5. On vehicles equipped with variable assist, connect the EVO electrical connector.

    6. Object Number: 862140 Size: SH

    Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  6. Raise vehicle on hoist.
  7. Install pressure and return hoses into steering gear.

    8. Tighten
    Tighten Power Steering Hoses-to-Steering Gear 27.5 N·m (20 lbs ft).

  8. Route hoses into the steering gear hose retaining clip, return hose first, pressure hose next. Secure hose in clip.
  9. Lower vehicle from hoist.

    10. Object Number: 860178 Size: SH

    Notice: Never overfill the power steering pump reservoir. Overfilling may cause contamination to accessory drive belt, generator, etc., resulting in premature failure.

  10. Fill power steering pump fluid reservoir with clean power steering fluid. Install reservoir fill cap.
  11. Install the accessory drive belt.
  12. Connect negative battery cable.

    13. Tighten
    Tighten Battery Terminal Bolts 17 N·m (13 lbs ft).

  13. Bleed power steering system. Refer to Power Steering System Bleeding .