Power-Assisted Steering Pump and Related Components

Power-Assisted Steering System

Section 9A - Power-Assisted Steering Pump and Related Components
Table of Contents
Power‑Assisted Steering Pump......................................... 9A-2 Power‑Assisted Steering—Hydraulic Hoses ..............9A-5
Removal......................................................................9A-2 Steering System Test.......................................................9A-11
Inspection................................................................... 9A-3 Power‑Assisted Steering System Pressure Test...... 9A-11
Installation...................................................................9A-3 Power‑Assisted Steering Pump Pressure Test.........9A-13
Power‑Assisted Steering System—Fluid Level.......... 9A-4

9
A

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Power-Assisted Steering Pump and Related Components

Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
28 Dexron III Automatic Power steering system Obtain Locally
Power Trim and Steering
114 Power steering system 92-858074K01
Fluid

Special Tools
Power Steering Pump Pulley Remover Kent Moore J‑21239

Removes the pulley on the DHB power steering pumps and water pumps with
smaller shafts.

25952

Pulley Pusher Installer 91‑ 93656A 1

Installs the pulley onto the power steering pump.

10047

Power Steering Test Gauge Kit 91‑38053A05

Tests the power‑assisted steering system pressure.

10804

Power‑Assisted Steering Pump

Removal
IMPORTANT: In the event of an internal pump failure the entire power‑assisted steering system must be replaced.
IMPORTANT: The pumps are non‑repairable units and are replaced with new units when they are found to be defective.

! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.

! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.

1. Disconnect the battery cables from the battery.

2. Remove the serpentine drive belt.
3. Remove the three screws securing the power‑assisted steering pump to the engine. Retain the screws.
4. Remove the fluid reservoir from the fluid reservoir bracket.

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! CAUTION
Contamination can damage the hydraulic system or cause the system to malfunction. Failure of power trim or steering
components can result in injury or product damage. Ensure that the work area, shop tools and all components are clean and
lint free during reassembly.
5. Drain the fluid from the power‑assisted steering pump and reservoir into a suitable container.
6. Do not reuse the fluid. Dispose of the fluid properly.

NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
7. Remove the reservoir hose and pressure hose from the power‑assisted steering pump. Cap or plug all open hydraulic
connections.

a - Power steering pump

c b - Pressure hose
c - Reservoir hose

a 21775

8. Using a suitable puller, remove the pulley from the power‑assisted steering pump shaft. Retain the pulley for installation.

12513

Typical

Power Steering Pump Pulley Remover Kent Moore J‑21239

Inspection
IMPORTANT: Always replace the O‑ring on the pressure hose fitting.
1. Inspect the power‑assisted steering pump pulley for warping and excessive wear.
2. Inspect the pressure hose fitting.
3. Inspect the return hose clamp.
4. Inspect the power‑assisted steering pump bracket for warping, cracks, and excessive wear.
5. Inspect the power steering fluid reservoir and cap for cracks, excessive wear, and signs of leaking.
6. Replace any components that do not pass inspection.

Installation
1. Install a new O‑ring on the pressure hose fitting.
2. Remove the caps or plugs from the hydraulic connections.
3. Install the reservoir hose and pressure hose onto the power‑assisted steering pump. Ensure that the new O‑ring is in
position on the pressure hose fitting.

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Power-Assisted Steering Pump and Related Components
4. Tighten the fitting to specification.

Description Nm lb. in. lb. ft.

Pressure hose fitting 31 – 23
5. Tighten the reservoir hose clamp securely.

a - Power‑assisted steering pump

c b - Pressure hose
c - Reservoir hose

a 21775

6. Install the reservoir onto the reservoir bracket.

7. Install the power‑assisted steering pump onto the pump bracket using the three screws retained in removal.
8. Tighten the screws to specification.

Description Nm lb. in. lb. ft.

Power‑assisted steering pump to pump bracket screw 26 – 19
9. Using the tool listed or a suitable screw and a flat washer, push (install) the pulley onto the power‑assisted steering pump
shaft until the pulley face is flush with the shaft end. The screw head and washer will make contact with the shaft end.

12514

Pulley installed flush with shaft end

Pulley Pusher Installer 91‑ 93656A 1

10. Drain any remaining fluid out of the power‑assisted steering reservoir into an approved container.
11. Do not reuse the fluid. Dispose of the old fluid properly.
12. Fill the power‑assisted steering reservoir with the specified fluid.

Tube Ref No. Description Where Used Part No.

28 Dexron III Automatic Power steering system Obtain Locally
Power Trim and Steering
114 Power steering system 92-858074K01
Fluid
13. Connect the battery cables.
14. Install the serpentine drive belt.

Power‑Assisted Steering System—Fluid Level

Checking
1. Stop the engine and center the sterndrive.

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2. Remove the fill cap from the power steering fluid reservoir and observe the level. The oil level should be at the lower mark
when the engine is cold and at the upper mark when the engine is warm.

a
a- Reservoir
c b- Add range
b c- Operating range
d- Fill cap

44889
3. Fill to the "FULL" line with the specified fluid.
IMPORTANT: If fluid is not visible in the fluid reservoir, locate and repair the leak.

Filling
1. Remove the fill cap/dipstick and observe the level.
2. Add the specified fluid to bring the fluid level up to the proper range.

Tube Ref No. Description Where Used Part No.

Dexron III Automatic
28 Power steering system Obtain Locally
Transmission Fluid
Power Trim and Steering
114 Power steering system 92-858074K01
Fluid
3. Reinstall the fill cap/dipstick.

Power‑Assisted Steering—Hydraulic Hoses

IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid from leaking.
IMPORTANT: Be careful to not cross‑thread or overtighten the hose fittings.

Pressure Hose (Pump-to-Control Valve)

Removal
NOTE: Catch any fluid that drains from the power‑assisted steering pump, hoses, fluid reservoir, or fluid cooler in a suitable
container.
1. Disconnect the the pressure hose from the power‑assisted steering pump.

a - Pressure hose fitting

b - O‑ring

b
21776

2. Remove and discard the O‑ring.

3. On models with standard fittings:
a. Disconnect the pressure hose from the control valve at the transom.

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Power-Assisted Steering Pump and Related Components

b. Remove and discard the O‑ring.

a - Pressure hose fitting

a b - Return hose fitting

b
21777

4. On models with quick‑connect fittings, disconnect the pressure hose from the quick‑connect fitting on the control valve
at the transom.

a - Pressure hose
a b - Return hose

6686

Installation
IMPORTANT: Route hoses as shown below to prevent kinks, which can damage hoses or fittings.
IMPORTANT: Be careful to not cross‑thread or overtighten the hose fittings.
1. Route the pressure hose to the control valve at the transom in the same position as prior to removal.
2. On models with standard fittings:
a. Ensure that the O‑ring is in position on the pressure hose fitting.
b. Install the threaded hose fitting into the control valve at the transom. Torque the fitting.

a - Pressure hose fitting

a b - Return hose fitting

b
21777

Description Nm lb. in. lb. ft.

Pressure hose fitting 31 23

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 Power-Assisted Steering Pump and Related Components

3. On models with quick‑connect fittings, install the pressure hose onto the quick‑connect fitting on the control valve at the
transom. Ensure that the quick‑connect fitting snaps into place.

a - Pressure hose
a b - Return hose

6686

4. Ensure that the O‑ring is in position on the pressure hose fitting at the power‑assisted steering pump.
5. Install the threaded hose fitting into the power‑assisted steering pump. Torque the fitting.

a - Pressure hose fitting

b - O‑ring

b
21776

Description Nm lb. in. lb. ft.

Pressure hose fitting 31 23
6. Fill the power‑assisted steering system with the specified fluid. See Section 1B.

Reservoir Hose (Reservoir to Pump)

Removal
NOTE: Catch any fluid that drains from the power‑assisted steering pump, hoses, fluid reservoir, or fluid cooler in a suitable
container.

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Power-Assisted Steering Pump and Related Components

1. Loosen the hose clamps on the reservoir hose at the reservoir and the power‑assisted steering pump. Remove the hose.

a- Reservoir
b- Hose clamp
a c- Reservoir hose
d- Power‑assisted steering pump
b

b c
d

21930

Installation
IMPORTANT: Route the hoses to avoid extreme heat, stress on the hose fittings, and hose kinks.
1. Using a hose clamp, install the new reservoir hose onto the reservoir. Tighten the clamp securely.
2. Using a hose clamp, install the new reservoir hose onto the pump. Tighten the clamp securely.

a- Reservoir
b- Hose clamp
a c- Reservoir hose
d- Power‑assisted steering pump
b

b c
d

21930

Return Hose (Cooler-To-Reservoir)

Removal
NOTE: Catch any fluid that drains from the power‑assisted steering pump, hoses, fluid reservoir, or fluid cooler in a suitable
container.
1. Loosen the hose clamp and remove the return hose from the fluid cooler.

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2. Loosen the hose clamp and remove the hose from the fluid reservoir.

a- Hose clamp
d b- Return hose
c- Fluid cooler
d- Reservoir
a
b

c
19549

Installation
IMPORTANT: Route the hoses to avoid extreme heat, stress on the hose fittings, and hose kinks.
1. Using a hose clamp, install the new return hose onto the reservoir. Tighten the clamp securely.
2. Using a hose clamp, install the return hose onto the fluid cooler. Tighten the clamp securely.

a- Hose clamp
d b- Return hose
c- Fluid cooler
d- Reservoir
a
b

c
19549

3. Fill the power‑assisted steering system with the specified fluid. See Section 1B.

Return Hose (Control Valve-to-Cooler)

Removal
NOTE: Catch any fluid that drains from the power‑assisted steering pump, hoses, fluid reservoir, or fluid cooler in a suitable
container.
1. Loosen the hose clamp and remove the hose from the fluid cooler.

a - Return hose

21787

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Power-Assisted Steering Pump and Related Components

2. On models with standard fittings,disconnect the return hose from the control valve at the transom.

a - Pressure hose
a b - Return hose

b
21777

3. On models with quick‑connect fittings,disconnect the return hose from the quick‑connect fitting on the control valve at
the transom.

a - Pressure hose
a b - Return hose

6686

4. Remove the return hose.

Installation
IMPORTANT: Route the hoses to avoid extreme heat, stress on the hose fittings, and hose kinks.
IMPORTANT: Be careful to not cross‑thread or overtighten the hose fittings.
1. Route the return hose to the control valve at the transom in the same position as prior to removal.
2. On models with standard fittings:
a. Ensure that the O‑ring is in position on the return hose fitting.
b. Install the threaded hose fitting into the control valve at the transom. Torque the fitting.

a - Pressure hose
a b - Return hose

b
21777

Description Nm lb. in. lb. ft.

Return hose fitting 31 23

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3. On models with quick‑connect fittings, install the return hose onto the quick‑connect fitting on the control valve at the
transom. Ensure that the quick‑connect fitting snaps into place.

a - Pressure hose
a b - Return hose

6686

4. Route the return hose along the flywheel housing and secure the hose with the J‑clamps provided.
5. Using a hose clamp, install the low pressure hose onto the fluid cooler. Tighten the clamp securely.

a - Return hose

21787
6. Fill the power‑assisted steering system with the specified fluid. See Section 1B.

Steering System Test

Power‑Assisted Steering System Pressure Test
The following procedure is arranged so that a defective part can be detected through the process of elimination. Follow the
order of the instructions so that the power‑assisted steering system can be tested effectively.

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Power-Assisted Steering Pump and Related Components
1. Remove the front and rear clevis pins.

c a- Clevis
b- Rear clevis pin (steering lever)
c- Front clevis pin
d- Steering cable end
b e- Cable guide tube
f- Cotter pins
a f
c

d
e

10272

2. Retract the cable into the cable guide tube.

3. Assemble and install the test gauge between the high‑pressure hose from the pump and the valve.

b a- Pump pressure hose

b- Test gauge assembly
c- Gauge‑to‑control‑valve hose
d- Control valve

a c

d
19481

Power Steering Test Gauge Kit 91‑38053A05

4. Open the valve on the gauge completely.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.

NOTE: For complete instructions for attaching a flush test device to the various water inlets, refer to Sterndrive Water
Pickups.

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5. Connect a flush test device to the sterndrive. Partially open the water tap (approximately half of maximum) and allow the
cooling system to fill completely. The cooling system is full when water is discharged through the propeller. Do not use full
water tap pressure.

10061

Standard Bravo shown

6. Start the engine and operate at 1000–1500 RPM until the engine reaches normal operating temperature.
7. With the engine at idle speed, the test gauge reading should be between 483 and 862 kPa (70 and 125 psi). If not,
proceed as follows:

NOTICE
Excessive operation can cause product damage. Do not lug the pump at maximum pressure for more than 5 seconds.
8. Push in and then pull the steering cable momentarily. Movement in each direction should cause the gauge to show an
instant increase in pressure.
9. Push the steering cable in until the booster cylinder piston rod is fully retracted. With the piston rod in this position,
momentarily push the steering cable in until its maximum pressure reading is reached.
• If the pressure is above 6897 kPa (1000 psi), system pressure is good.
• If the pressure is below 6897 kPa (1000 psi), conduct the Power‑Assisted Steering Pump Pressure Test.

Power‑Assisted Steering Pump Pressure Test

1. Install a test gauge between the high‑pressure hose from the pump and the valve.

b a- Pump pressure hose

b- Test gauge assembly
c- Gauge‑to‑control‑valve hose
d- Control valve

a c

d
19481

Power Steering Test Gauge Kit 91‑38053A05

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.

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Power-Assisted Steering Pump and Related Components
NOTE: For complete instructions for attaching a flush test device to the various water inlets, refer to Sterndrive Water
Pickups.
2. Connect a flush test device to the sterndrive. Partially open water tap (approximately half of maximum) and allow water to
enter the cooling system. Do not use full water tap pressure.

10061

Standard Bravo shown

3. Start the engine and operate at 1000–1500 RPM until the engine reaches normal operating temperature.
IMPORTANT: The test gauge valve blocks the flow of pressurized fluid when closed. To avoid damage to the pump, do not
close the test gauge valve longer than five seconds during testing.
4. Close the test gauge valve just long enough to obtain maximum pressure reading.
5. Close and open the valve three times. Record the highest pressure reading attained each time:
a. If pressure readings are between 9308 and 9997 kPa (1350 and 1450 psi) and are within a range of 345 kPa
(50 psi), the pump is within specifications. If the pump tests OK, but system pressure was low (as tested under
Power‑Assisted Steering System Pressure Test) replace the control valve assembly.
b. If pressure readings are between 9308 and 9997 kPa (1350 and 1450 psi) but are not within a 345 kPa (50 psi)
range, the power‑assisted steering pump flow control valve is sticking or the pump hydraulic system is dirty.
c. If pressure readings are constant, but below 8963 kPa 1300 psi, replace the power‑assisted steering pump.

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