Specifications

A power assisted, high ratio, steering rack system
has been designed and developed as a complete
package for the Group A car. This includes the
steering rack, steering pump, external power
ram, oil reservoir, mounting brackets, all oil
pipes and fittings. The power assistance
characteristics closely match those developed for
the Group A Kadett GSi and Astra GTE models.
This minimises the torque steer effects usually
associated with high powered front wheel drive
cars and considerably reduces driver fatigue.
INSTALLATION
Before attempting to fit the steering rack
assembly, the hole in the bulkhead where the
steering column enters the engine compartment
must be enlarged significantly to accommodate
the power steering valve body. A template of
this hole is provided as a single removable page
in the rear of the manual. To prevent the
possibility of the power assistance ram becoming
loose at its attachment points on to the actual
steering rack, the two bolts must be removed and
drilled prior to reassembling, and then safety
wired.
The steering rack assembly can now be
placed on its mountings, but before tightening
the securing nuts establish that the rack body sits
correctly on the bulkhead mounting positions.
Tolerances in the body shell may dictate that
some metal may have to be removed from the
steering rack body to improve this condition.
The steering rack can now be attached to the
bulkhead. A body sealing rubber gaiter is
provided and fits over the valve body from the
inside of the vehicle prior to fitting the column
assembly. This gaiter will require slight
,
trimming' to achieve a satisfactory fit around the
valve body, prior to attaching it permanently to
the bulkhead using adhesive or other means.
The oil reservoir can be attached to the left hand
suspension turret using the bracket supplied. All
the pipes are made to the correct length and have
the appropriate end fittings such that they can
only be fitted in the correct way.
The power steering pump is attached to the
engine by two bolts and driven from the
crankshaft pulley by a common `poly-vee' drive
belt that also drives the alternator.
Two universal joints and two mini-shafts are
provided to connect the steering column to the
power steering rack assembly. One shaft fits
between the two U.J's, the other fits into the end
of the steering column having first removed and
discarded the original lower column shaft.
NOTE: On certain vehicles, the replacement
l ower column shaft may require further
machining before it can be correctly fitted into
the existing lower column support bush. In this
case refer to the diagram showing the revised,
machined condition.
The steering column can now be connected
to the power steering rack by attaching the two
U.J's. Tighten all clamping bolts thoroughly!
Initially the system will require bleeding to
remove any air pockets. Top up the pump
reservoir with new fluid (Dexron 90 020 172), to
the edge of the filler neck. Start engine and
i mmediately switch off, repeating this procedure
until the fluid level is at the `MIN' mark with the
engine stationary. To bleed the system, start
engine and allow to idle whilst the steering wheel
is turned from lock to lock. Finally check the
fluid level in the system when the system is cold
and the engine not running. The level should
then reach the `MIN' mark. At normal operating
temperature the level should not be above the
'
MAX' mark. If the fluid level drops particularly
low, check the system for leaks. Under no
circumstances allow the pump to be driven with
insufficient or no fluid in the system.
NOTE: Do not use the vehicle with the power
assistance disconnected, this could lead to
damage within the valve assembly.