Tuesday, March 8, 2011

1999 Volvo S80 t6 power steering and pump replacement?

CAUTION:--
Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

POWER STEERING PUMP BLEEDING:---
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. With engine off, turn the steering wheel fully to the right and left several times.
    NOTE
    Do not allow the fluid level in the reservoir tank to go below the MIN level line. Check and add fluid as needed.

  3. Run the engine at idle speed. Turn the steering wheel fully to the right and then fully to the left. Hold for about three seconds. Check for fluid leakage.
  4. Repeat the above step several times at three second intervals.
    NOTE
    Do not hold the steering wheel in the locked position for more than ten seconds.

  5. Check for air bubbles or cloudy fluid. If found, repeat the bleeding procedure.
  6. Stop the engine and check the fluid level. Fill as required.


POWER STEERING PUMP REMOVAL AND INSTALLATION:---
WARNING
Used fluid is considerably more dangerous than new fluid. Avoid skin contact with the oil.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the accessory drive belt. Refer to Accessory Drive Belts removal and installation.
  3. Drain the power steering pump oil:
    1. Install a lock-grip pliers on the hose from the fluid reservoir as close to the power steering pump as possible.
    2. Extract the oil.
      NOTE
      Place a covering over the alternator as protection against oil.


  4. Remove or disconnect the following:

    The pressure hose
    The feeder hose

    Click image to see an enlarged view

    Fig. Removing hoses from power steering pump with lock-grip pliers in place

    Removing hoses from power steering pump with lock-grip pliers in place

  5. Remove the mounting bolts from power steering pump.
  6. Remove the power steering pump.

To install:

  1. Installation is the reverse of the removal procedure.
  2. Install the power steering pump with the M8 mounting bolts. Tighten to 18 ft. lbs. (24 Nm).
  3. Install the pressure hose and feeder hose with the M6 bolts. Tighten to 88 inch lbs. (10 Nm).
    NOTE
    Use a new O-ring.

  4. Install the accessory drive belt. Refer to Accessory Drive Belts removing and installation.
  5. Refill oil using Volvo power steering fluid, P/N 1161529.
  6. Bleed the power steering system. Refer to Power Steering Pump bleeding.

STEERING WHEEL REMOVAL AND INSTALLATION:---

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect negative battery cable.
    WARNING
    Under no circumstances use an ohmmeter or other live measuring instrument to take readings on a disconnected, non-deployed pyrotechnical Supplemental Restraint System (SRS) component. There is also a risk of the seat belt tensioner deploying. Pyrotechnical SRS components must never be taken apart, repaired, or transferred to another vehicle.

  3. Remove the air bag module:
    1. With battery disconnected, move the ignition key to Position II.
    2. Turn the steering wheel 1 / 4 turn so that the two holes on the rear of the steering wheel are accessible.
    3. Insert a screwdriver in the holes on the reverse of the steering wheel. The screwdriver must be at a right-angle to the rear surface of the steering wheel.
    4. Place the screwdriver point against the top of the spring clip as illustrated.
    5. Pry the screwdriver up against the upper edge of the hole (2) so that the point of the screwdriver presses down the catch (1) until the catch releases.
    6. Turn the steering wheel 1 / 2 turn in the opposite direction.
    7. Repeat the process on the other side.
    8. Turn the steering wheel to the neutral position.
    9. Fold out the air bag.
    10. Disconnect the 2 connectors (there may be more or less) for the SRS ignition cables for the air bag.
    11. Remove the air bag.
      CAUTION
      The removed air bag module should be stored in a clean, dry place with the pad cover face up.



      Click image to see an enlarged view

      Fig. Placing ignition key into Position II with battery disconnected

      Placing ignition key into Position II with battery disconnected

      Click image to see an enlarged view

      Fig. Position of steering wheel for access to air bag module retaining clips

      Position of steering wheel for access to air bag module retaining clips

      Click image to see an enlarged view

      Fig. Releasing spring retaining clip for driver-s side air bag module

      Releasing spring retaining clip for driver-s side air bag module

      Click image to see an enlarged view

      Fig. Disconnecting the SRS ignition cables for the air bag module

      Disconnecting the SRS ignition cables for the air bag module

  4. Lock the contact reel in position with the locking screw as illustrated.
  5. Remove the bolt securing the steering wheel to the steering column.
  6. Pull the steering wheel straight back.
  7. Pull the cable harness through the hole in the steering wheel.
  8. Remove the steering wheel.

    Click image to see an enlarged view

    Fig. Locking the contact reel and removing steering wheel

    Locking the contact reel and removing steering wheel

To install:

  1. Pull the cable harness through the hole of steering wheel.
  2. Install the steering wheel in place.
  3. Install the center bolt for the steering wheel. Use a new bolt. Tighten in 2 steps:
    1. Step 1-22 ft. lbs. (30 Nm).
    2. Step 2-angle-tighten 30°

  4. Remove the locking screw holding the contact reel.
  5. Install the air bag module:
    NOTE
    For air bags (replacement part) supplied without keypads, for Audio, RTI, and cruise control, an upgrade kit must be ordered.

    1. Install the 2 connectors (there may be more or fewer).
    2. Press the air bag into place.
      CAUTION
      Ensure that the wiring is not trapped during installation.


  6. Check that the SRS is functioning properly:
    1. Install the battery negative lead.
    2. Check that the SRS indicator lamp is not defective by turning the key to Position II.
    3. The SRS indicator lamp must light and go out after approximately seven seconds.
    4. Check that the SRS indicator lamp in the combined instrument panel is not constantly lit. Fault-trace the SRS if the lamp is constantly lit.


    POWER RACK PINION STEERING GEAR:-----
    REMOVAL AND INSTALLATION:---

    1. Before servicing the vehicle, refer to the Precautions section.
    2. Separate the steering gear from the steering column by lifting the floor carpet below the steering column and remove the pinion shaft bolt.
    3. Remove or disconnect the following:

      Right front wheel
      Lower ball joints
      Center cross member
      Front exhaust pipe
      Rear engine mount
      Heat deflector plate
      Steering gear left mounting bracket
      Power steering hoses
      Steering gear right mounting bracket

    4. Slide the steering gear housing to the right and lower the assembly to remove.

    To install:

    1. Install or connect the following:

      Steering gear
      Steering gear right mounting bracket and tighten the bolts to 51 ft. lbs. (69 Nm)
      Power steering hoses with new O-rings
      Steering gear left mounting bracket and tighten the bolts to 51 ft. lbs. (69 Nm)
      Heat deflector plate and tighten to 88 inch lbs. (10 Nm)
      Front exhaust pipe
      Right front wheel
      Pinion shaft


    1. Before servicing the vehicle, refer to the precautions in the beginning of the section.


    NOTE
    Ensure the steering wheel is set to -straight ahead- position and remove the key so the steering wheel lock engages.

    1. Remove the left front wheel and measure and record the length of the tie rod in relation to the steering gear housing.
    2. Remove or disconnect the following:

      Driver-s side soundproofing panel
      Left front wheel
      Steering shaft from the steering gear
      Sub-frame
      Powering steering hoses from the steering gear

    3. Slacken off the nut for the outer steering arm. Press the steering arm out of the wheel spindle using special tool 951-2945 or equivalent.
    4. Remove the steering gear.


    5. Click image to see an enlarged view

      Fig. Pull the steering arm from the wheel spindle.

      Pull the steering arm from the wheel spindle.

    To install:

    1. Install or connect the following:

      Steering gear
      Outer steering arm, tighten nuts to 37 ft. lbs. (50 Nm)
      Power steering hoses using new O-rings
      Sub-frame
      Steering shaft to the steering gear
      Wheel
      Soundproofing panel

    2. Fill and bleed the power steering system.

    1. Before servicing the vehicle, refer to the Precautions section.


    NOTE
    Do not turn the front wheels so that the steering gear position is changed. The SRS-system contact reel can be damaged.

    1. Raise and support the engine.
    2. Remove or disconnect the following:

      Front wheels
      SRS connector, if equipped Disconnect the connector cable from the clips along the ABS cable. Push down the connector and cable to the steering gear.
      Outer tie rod ends
      Splash guard
      Exhaust pipe bracket

    3. Support the subframe with a jack
    4. Remove the side and rear subframe bolts and loosen the front subframe bolts.
    5. Remove the heated oxygen (HO2S) sensor bracket, 6-cylinder engines only
    6. Lower the rear edge of the sub-frame approximately 3.5 inches (90 mm). Ensure that the steering gear screws are released from the sub-frame.
    7. Remove or disconnect the following:

      Rear engine mount
      Power steering hoses
      Steering shaft coupler

    8. Slide the steering gear to the left and lower the assembly to remove.

    To install:

    1. Slide the steering gear in from the left hand side.
    2. Install or connect the following:

      Power steering hoses using new O-rings.
      Steering shaft coupler and tighten to 15 ft. lbs. (20 Nm)
      Rear engine mount and tighten to 37 ft. lbs. (50 Nm)
      Subframe. Use new bolts and tighten them to 77 ft. lbs. (105 Nm) plus 120 degrees.
      Subframe brackets and tighten to 37 ft. lbs. (50 Nm)
      Heated oxygen (HO2S) sensor bracket, 6-cylinder engines only
      Exhaust pipe bracket and tighten to 18 ft. lbs. (25 Nm)
      Outer tie rod ends
      Splash guards
      SRS connector, if equipped
      Front wheels


    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2. Install a support fixture to the engine lifting eyes.
    3. Remove or disconnect the following:

      Negative battery cable
      Front wheels
      Outer tie rod ends
      Splash guards
      Power steering hose brackets
      Steering gear mounting nuts
      Subframe brackets

    4. Support the subframe with a jack.
    5. Loosen the front subframe bolts and remove the rear subframe bolts.
    6. Remove or disconnect the following:

      Power steering hoses
      Steering shaft coupler
      Steering gear


    To install:

    1. Install or connect the following:

      Steering gear
      Steering shaft coupler and tighten the bolt to 15 ft. lbs. (20 Nm)
      Power steering hoses
      Subframe. Use new bolts and tighten them to 77 ft. lbs. (105 Nm) plus 120 degrees.
      Subframe brackets and tighten the bolts to 37 ft. lbs. (50 Nm)
      Steering gear mounting nuts. Use new nuts and tighten them to 37 ft. lbs. (50 Nm).
      Power steering hose brackets
      Splash guards
      Outer tie rod ends
      Front wheels
      Negative battery cable

    2. Fill the power steering fluid reservoir with fluid.
    3. Check the wheel alignment and adjust as necessary.

    1. Before servicing the vehicle, refer to the Precautions section.
    2. Install a support fixture to the engine lifting eyes.
    3. Remove or disconnect the following:

      Negative battery cable
      Front wheels
      Outer tie rod ends
      Splash guards
      Power steering hose brackets
      Steering gear mounting nuts
      Subframe brackets

    4. Support the subframe with a jack.
    5. Loosen the front subframe bolts and remove the rear subframe bolts.
    6. Remove or disconnect the following:

      Power steering hoses
      Steering shaft coupler
      Steering gear


    To install:

    1. Install or connect the following:

      Steering gear
      Steering shaft coupler and tighten the bolt to 15 ft. lbs. (20 Nm)
      Power steering hoses
      Subframe. Use new bolts and tighten them to 77 ft. lbs. (105 Nm) plus 120°.
      Subframe brackets and tighten the bolts to 37 ft. lbs. (50 Nm)
      Steering gear mounting nuts. Use new nuts and tighten them to 37 ft. lbs. (50 Nm).
      Power steering hose brackets
      Splash guards
      Outer tie rod ends
      Front wheels
      Negative battery cable

    2. Fill the power steering fluid reservoir with fluid.
    3. Check the wheel alignment and adjust as necessary.

    1. Before servicing the vehicle, refer to the Precautions Section.
    2. Separate the steering gear from the steering column by lifting the floor carpet below the steering column and remove the pinion shaft bolt.
    3. Remove or disconnect the following:

      Right front wheel
      Lower ball joints
      Center cross member
      Front exhaust pipe
      Rear engine mount
      Heat deflector plate
      Steering gear left mounting bracket
      Power steering hoses
      Steering gear right mounting bracket

    4. Slide the steering gear housing to the right and lower the assembly to remove.

    To install:

    1. Install or connect the following:

      Steering gear
      Steering gear right mounting bracket and tighten the bolts to 51 ft. lbs. (69 Nm)
      Power steering hoses with new O-rings
      Steering gear left mounting bracket and tighten the bolts to 51 ft. lbs. (69 Nm)
      Heat deflector plate and tighten to 88 inch lbs. (10 Nm)
      Front exhaust pipe
      Right front wheel
      Pinion shaft


    1. Before servicing the vehicle, refer to the precautions in the beginning of the section.
      NOTE
      Ensure the steering wheel is set to -straight ahead- position and remove the key so the steering wheel lock engages.

    2. Remove the left front wheel and measure and record the length of the tie rod in relation to the steering gear housing.
    3. Remove or disconnect the following:

      Left side soundproofing panel
      Left front wheel
      Steering shaft from the steering gear
      Sub-frame
      Powering steering hoses from the steering gear

    4. Slacken off the nut for the outer steering arm. Press the steering arm out of the wheel spindle using special tool 951-2945 or equivalent.
    5. Remove the steering gear.

      Click image to see an enlarged view

      Fig. Pull the steering arm from the wheel spindle.

      Pull the steering arm from the wheel spindle.

    To install:

    1. Install or connect the following:

      Steering gear
      Outer steering arm, tighten nuts to 37 ft. lbs. (50 Nm)
      Power steering hoses using new O-rings
      Sub-frame
      Steering shaft to the steering gear
      Wheel
      Soundproofing panel

    2. Fill and bleed the power steering system.

    1. Before servicing the vehicle, refer to the Precautions Section.
      NOTE
      Do not turn the front wheels so that the steering gear position is changed. The SRS-system contact reel can be damaged.

    2. Raise and support the engine.
    3. Remove or disconnect the following:

      Front wheels
      SRS connector, if equipped Disconnect the connector cable from the clips along the ABS cable. Push down the connector and cable to the steering gear.
      Outer tie rod ends
      Splash guard
      Exhaust pipe bracket

    4. Support the subframe with a jack
    5. Remove the side and rear subframe bolts and loosen the front subframe bolts.
    6. Remove the heated oxygen (HO 2 S) sensor bracket, 6-cylinder engines only
    7. Lower the rear edge of the sub-frame approximately 3.5 inches (90mm). Ensure that the steering gear bolts are released from the sub-frame.
    8. Remove or disconnect the following:

      Rear engine mount
      Power steering hoses
      Steering shaft coupler

    9. Slide the steering gear to the left and lower the assembly to remove.

    To install:

    1. Slide the steering gear in from the left hand side.
    2. Install or connect the following:

      Power steering hoses using new O-rings.
      Steering shaft coupler and tighten to 15 ft. lbs. (20 Nm)
      Rear engine mount and tighten to 37 ft. lbs. (50 Nm)
      Subframe. Use new bolts and tighten them to 77 ft. lbs. (105 Nm) plus 120°.
      Subframe brackets and tighten to 37 ft. lbs. (50 Nm)
      Heated oxygen (HO 2 S) sensor bracket, 6-cylinder engines only
      Exhaust pipe bracket and tighten to 18 ft. lbs. (25 Nm)
      Outer tie rod ends
      Splash guards
      SRS connector, if equipped
      Front wheels