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[Zafira A] [99-05] Replacing Power steering rack information

Discussion in 'Astra, Corsa, Zafira, Meriva, Adam, Agila, Tigra & Nova [Includes AstraVan & ComboVan] owners forum' started by velojunkie, Feb 1, 2010.

  1. velojunkie

    velojunkie Member

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    Location:
    Tamworth UK
    Drives:
    Zafira A
    Hi All
    I just wanted to share something with all the Zafira A owners and I hope it will be helpfull.
    I had lost powersteering on my Zafira and with money being a tight I had to try find a solution fast because my wife could not drive the car. I looked online to try find help and prices. I couldn't afford a new pump or recon unit for that matter or pay to have someone do the work for me. I have a Haynes manual and they speak about removing the subframe to remove the powersteering pump. You need some special equipment for this which I don't have. I had the second generation TRW pump fitted , so I was lucky enough to find a steering rack and pump off a 2008 Astra Sxi on ebay for £ 150-00 which I eventually got for £135-00. I will try to resell the steering rack later.The pumps look the same so I was hoping my gamble would pay off.
    Now to the point. I was able to remove the pump without removing the subframe with no real difficulty and I was able to use the 2008 pump , I just swapped over the fuse holder , multiplug and battery connections. It works great and hope I get a couple more years service. If you want to attempt the same thing as I did or have any questions please don't hesitate.
    Best Regards
     
    DrewKrewUK and cavwebmaster like this.
  2. cavwebmaster

    cavwebmaster CavWeb/VxON Forums Admin & Founder Staff / Administrator VxON Club Member

    Messages:
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    Location:
    Nottingham
    Drives:
    Modified Astra H Sporthatch 150 CDTI
    Any more information in making this an easier process would be welcome mate ;)
     
  3. velojunkie

    velojunkie Member

    Messages:
    10
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    Location:
    Tamworth UK
    Drives:
    Zafira A
    Hi again.
    I am going to try explain how I went about replacing the pump.
    First I removed the battery. I then removed the plastic cover that covers the engine. I removed the small return feed pipe to the coolant expansion bottle and moved it out of the way because it is in front of the fuse holder and it made working just a bit easier.Next I removed the battery tray.I then removed the fuse holder cover and uncliped the fuse box from its mounting plate as well as the large harness coupling you can see just in front of it. I then removed the fuse for the pump (No 7) and the holder (pink). You have to push it up and out from the bottom and you have to use a reasonable amount of force , but with enough pressure it should just unclip and move up. I made a mental note of how the powersteering pump harness was routed and I loosened it from its body cable ties. I used a large syringe and tube to suck out as much powersteering fluid as I could from the reservoir.I put an old carpet under the car and then removed the factory fitted clip from the return line pipe that feeds fluid back to the reservoir. I then removed the pressure pipe. The nut is loosened with an 18mm spanner and loosened easily. Any oil that came out fell onto the old carpet but there wasn't much.The hardest part is getting to the 10mm nuts (3 of them) that hold the pump to the mounting bracket , and you will see the three small rubber mountings. Once the three mounting nuts are loose it is ready to come out. Now there is steel brake lines around the pump but I assure you that if you manouver the pump slowly and carefully , it will come out. I laid the pumps side by side and found the harnesses are slightly different but equal in length. The old pump had the fuse holder (on the red wire) , a small three wire multiplug and a big battery connection terminal on the brown wire. The new pump had no fuse holder fitted to the red wire and a smaller battery connection terminal on the brown wire. The multiplug was larger on the new pump but the wire colours were the same and there were only three wires , same as the old pump. All I did was snip of the old multiplug and solder it onto the new harness as well as the fuse holder and brown wire battery terminal. Refitting was just in reverse order and I carefully refitted the harness and made sure it was not being shaved on any of the body.I used the syringe again to fill the reservoir with new oil (green) refitted battery tray , battery etc connected everything and started the car. To my relief the pump was running and we again had powersteering. I made sure there was no air in the system by turning full lock to full lock a couple of times and then road tested it. I hope this will help and save you money because it saved me a whole bunch.
    Regards
    Velojunkie
     
  4. FISCUSK

    FISCUSK New Member

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    Location:
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    Yup i managed to get mine out the top, as all garages i got a quote from, said subframe outjob!

    Only extra thing I did was remove diesel filter, just gives a bit more room. but they are a pain to get started again. A lack of priming pump just leaves lots of cranking it over to get diesel moving, and keep topping filter housing up, eventualy it will fire.

    As for topping it up with oil, Local part shop could not tell me what to put in it, so i phoned vauxhall dealer, they gave me a part number, still no oil spec. service or parts could not tell me other than they had it on a shelf, for £xx. So i just put ATF in, which i had, and was one of the opitons local parts shop spec'd. Its all working well, I got a £30 pump from a astra, off ebay!
     
    Stewart T likes this.
  5. cavwebmaster

    cavwebmaster CavWeb/VxON Forums Admin & Founder Staff / Administrator VxON Club Member

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    Location:
    Nottingham
    Drives:
    Modified Astra H Sporthatch 150 CDTI
    Thanks Colin (y) I'm sure it will help other people attempting to remove their own rack :)
     
  6. vectraowner

    vectraowner Active Member

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    Location:
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    was there any pre-warnings before it died ?

    Asking because my PAS pump is rather noisy and i dont know if it is because it is on it's way out. When the car is in the driveway and idling i can hear the PAS pump and if i turn the steering wheel ever so slightly to either side it whines louder.

    Have tried putting more ATF fluid into the reservoir but i dont really know how to see if there is enough or not and since i dont think i am loosing any fluid i dont know any other reason for the noise...Oh and the noise did not get any less when i put in more fluid..

    Power steering works fine but just mildly concerned that it might die on me some day.

    PS. I drive Zafira A just like you.

    Vectraowner
     
  7. velojunkie

    velojunkie Member

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    Location:
    Tamworth UK
    Drives:
    Zafira A
    There were no warnings , just stopped working. Mine was not noisy at all.

    I found that mine had blown a trasnsistor or something because of a bit of moisture in the pump electrics.

    I think your pump is showing signs of wear. If you want to keep the car replace both pump and rack when the old pump fails. Metal contamination in the system's oil will damage a new pump and then your back to square one.

    If you not going to keep the car long , sell it on and let the new owner decide.

    Hope this helps

    Regards
     
  8. Delbert

    Delbert Well-Known Member

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    Location:
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    Thanks for the info.

    Mines an Astra which appears to have a similar subframe arrangement, which to me seems like a simple issue complicator (a word I can't find in my dictionary, so I've just invented it) - nay, a pain in the bum.

    P.S. has anyone done a starter motor replacement?
     
  9. vectraowner

    vectraowner Active Member

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    Location:
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    Found a product called "ABCON Power steering treatment " which supposedly lubricates the power steering and helps reduce noise, reduces friction and whatnot.

    Do you think it will be a waste of money trying out this product ?

    Vectraowner
     
  10. rik007

    rik007 New Member

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    Location:
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    Hi, just to say thank you for your detailed explanation of extracting the Steering Pump on a Zafira!!

    I think you have just saved me hundreds of £'s.

    I have the same problem, steering pump packed up on my 2001 1.8 Zafira, got a £1000 quote from the garage for new rack and pump - which is more than the car is worth!

    I had read various info about removing the subframe to get at the pump, but really didnt want to get that invloved. The Zafira is a great car we really enjoy using it, drives well, loads of space etc but at the end of the day its only a £1500 car.

    But with your info I shall hopefully get the TRW pump out and find out if its Gen1 or Gen2 and grab a replacement.

    So, excellent info well detailed, thanks for your contribution.

    Rich.
     
    Stewart T likes this.

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