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 Post subject: KJ 3.7L power steering high pressure hose R&R
PostPosted: Sat Dec 03, 2016 6:05 pm 
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Location: North America
Don't know if this is useful, but at least the exploded pics of the *^@# PS high-pressure hose pressure-regulator may save a headache or two if they fall out unsupervised.

Tools: 10/13/16/18/22mm Wrenches: “stubbies” and “hose” wrenches very helpful. Small “Robogrips” also very helpful. Something to catch draining P/S fluid: oil-change pan, or cut a plastic gallon water jug in half to catch and reuse fluid.

Due to moderately difficult access, this basic r&r requires patience.

Removing the serpentine belt vastly eases/speeds removal of the high pressure hose at the PS pump: 13mm to loosen adjuster mounting bolts, then just lift-up on spring-loaded adjuster pulley until belt is removable. If the old serp belt has been contaminated by PS fluid, you should replace it after all work to the PS system is completed, using clean tools, gloves and hands.
Also, removing the oil filter greatly improves access for removing the high-pressure hose at the steering rack (change oil while you're at it?).
If you are replacing a damaged high-pressure hose, to ease removal you may want to consider using a sawzall to very carefully cut the old hose at its metal ends, permitting removal using sockets instead of wrenches:
Image
If so, be extremely careful not to damage adjacent hoses, human body parts, etc.

If you are completely removing or replacing the high-pressure hose, you may want to use a hole saw to “modify” the left front headlight housing, vastly easing removal of the 2 10mm mounting bolts at the cooling “U” located mid-hose under the left headlight:
Image


Link to holesaw mod video:
https://youtu.be/m8_E-Pgp5VI
No obvious negative consequences, but your call.
Obviously, you need to remove the headlight first (2 10mm bolts) if you're going to do hole-mod.
If no hole-mod, this is your access for R&Ring those 2 pita bolts (vid above also conveys difficulty of access without hole-mod. Ignore sad green flashlight):
Image

First remove the high-pressure hose connection located facing downward on the bottom of the PS pump. The hose fitting is 16mm, and limited-access makes a stubby wrench advisable; once loose, small Robogrips greatly speed complete removal.
Stay alert, because there’s a (slim) chance that you may also be unscrewing the 22mm “pressure regulator” fitting when loosening the 16mm hose fitting. You’ll know if this happens because it will be unusually difficult to rotate the 16mm fitting; once it is “cracked” loose, that 16mm fitting should rotate off fairly easily by hand while gently jiggling the hose.
Once off, you can move the hose clear of the PS pump, allowing 22mm socket access for removal of the pressure regulator fitting. It does not face straight down, instead it is slightly angled towards the right-side of the vehicle. If it's stubborn you may have to use a wobbly and extensions to gain under-vehicle access for a breaker-bar to start removal.

Here's the tricky part: as you unscrew that fitting, keep in mind that it is the only thing preventing the pressure regulator and it's spring from dropping out the bottom of the PS pump. So be prepared to either catch those two buggers or have something draped beneath to catch them. You want to keep them clean.
Here's a pic of how the fitting, pressure regulator, and spring fit together:
Image

Pic below shows disassembled pressure regulator, permitting cleaning of it's cap-screen and other components. Don't lose the ball bearing!
Exploded view of component sequence:
Image

Removing the high-pressure hose's 18mm fitting at the steering rack is much easier & quicker with the oil filter removed; otherwise, you've barely got room for 1/8th-turn wrench-rotation.

If completely removing the hose and reusing the old hose or replacing with a used hose, use air to blow the hose clean before installation.

After installation, fill reservoir to "Max-Cold" line, start vehicle, repeatedly steer left-right to full-lock, turn-off engine and add fluid as necessary.
After driving, check for leaks and inspect fluid level.


Keywords: Power steering pump pressure regulator, power steering high pressure hose, P/S hose, troubleshooting power steering, high-pressure hose R&R.

_________________
'15: bought '05 w/138k.
'16: HG/Rockers/ARPs/Thermo/H20pump/TbeltKit/ Seals/ Mounts/Kennedy fuel pump.
'17: bought manual Gas donor for its' ARB F/R Airlockers, OME 2.5" lift (gas-rated), JBA UCAs, ARB bumper.
'19: Trans w/Suncoast/Transgo/HDdiscs, new OME CRD-rated lift, electric tri-fan setup, BlackMagics/Centric Premiums, Airbags.


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