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Old 03-27-2012, 02:09 AM   #1 (permalink)
TPI Monte SS

Join Date: Mar 2009
Location: North Jersey
Posts: 79
Thumbs up HOW TO: Power Steering Pressure Line Install ('03 Limited)

Here's another way to install a high pressure power steering line. This was done on my wife's '03 KJ Limited without HD cooling.

Tools Needed:

15mm socket on breaker bar (to remove serpentine belt)
16mm and 18mm flare wrench (for power steering line fittings)
14mm box wrench (for power steering pressure switch if equipped)
1/4" drive 10mm socket, swivel joint, and 12" extension (for power steering line bracket bolts)
Flathead screwdriver
T20 Torx screwdriver
Dremel with cutoff wheel
Magnetic wand

Here's a pic of the offending line - note the wet spot where the rubber hose is crimped into the fitting. My wife's KJ only has 45K miles, but it is almost 10 years old, so I guess it was due.

Personally, if you can wait to do the job when you're due for an oil change, it'll make life a little easier. The oil filter is in the way and needs to be removed so you can get to the fitting on the power steering line. Also, removing the serpentine belt will gain you a little room to work as well. To remove it, you need a 15mm socket on a breaker bar - put it on the bolt that goes throug the middle of the tensioner pulley, then push down on the tensioner to release the belt.

Now, I wasted a lot of extra time trying to reach the bracket from inside the engine bay, and finally went a different direction. This is much easier!

First step, remove the grill. There are 4 T20 screws across the top, and then it is hooked into the bumper cover below. Just rotate it down and it should pop out without any issue. Next, remove the headlight assembly. There are 2 T20 screws holding it in.

And here's a closeup of the area just below the headlight bezel, and behind the harness that runs across the grill support. I used a cutoff wheel on my Dremel to remove a 1" square section of the grill support to gain access to the bolts holding the power steering line bracket in place.

Now, here's a shot looking inside the hole. You can access one bolt through here, and the other through the factory opening right next to it. Use the 10mm socket on a swivel joint to get in there and remove the bolts. A magnetic wand is your friend too, to grab the bolts.

Once the bolts holding the bracket are out, you can loosen the fittings to remove the line. On the earlier KJs ('02-'03) there's a power steering pressure switch. Disconnect the harness and move it out of the way. The fitting down by the rack is 18mm. Once you pull it, some fluid will start to dribble out.

The fitting under the power steering pump is 16mm, and is relatively easy to reach as well. Once this one is removed, the pump will puke out whatever
fluid is left in the reservoir.

Once all the fittings are removed, you can fish the line out.

I bought a new line from Autozone, which included a new bracket. They give you all the hardware to build the bracket, and a plug for the hole in case you don't need the pressure switch.

You'll need to swap over the grommets where the bracket gets mounted to the body. Use a flathead screwdriver to separate the metal sleeve and then slide the grommet out.

Swap the grommets over to the new bracket, and swap your pressure switch (if equipped) over. Use a new O-ring; you can pilfer it off the supplied plug.

You need a 14mm box wrench to R&R the switch.

Installation is reverse of removal - connect the fittings first, then line up the bracket and bolt it down. Here's a few pics of the finished assembly.

Now refill the reservoir, and reinstall the headlight and grill. Don't forget your oil filter and serpentine belt. Start it up, check for leaks, and watch the fluid level in the reservoir. Top off as necessary.

Hope this helps!!
Steve - North Jersey
'06 G35x - a few mods...

'03 KJ Limited - only 45K miles, Mopar slushmats, '06 KJ Limited 17's.

Last edited by TPI Monte SS; 03-27-2012 at 02:15 AM.
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