Power Steering Pump Pulley

This procedure covers removal and installation of the power steering pump pulley on a 2015 Kia Forte with 1.8L I4 engine, typically performed when replacing the pump or pulley.

Warnings

Tools required

Parts

• Power steering pump pulley × 1 — Use OEM specification
• Power steering fluid O-rings × 2 — Use OEM specification
• Kia PSF-4 power steering fluid × 1 — Use OEM specification

Fluids

• Kia PSF-4 — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Remove power steering reservoir cap to relieve any pressure
4. Use fluid transfer pump or turkey baster to remove as much fluid as possible from the power steering reservoir
5. Place drain pan under power steering pump area

Procedure

1. 1

   Remove serpentine drive belt
   Locate the serpentine belt tensioner on the front of the engine. Using a serpentine belt tool or appropriate socket, rotate the tensioner clockwise to release tension. Slide the belt off the power steering pump pulley first, then remove from remaining pulleys. Note the belt routing diagram on the radiator support for reinstallation.
2. 2

   Disconnect power steering pressure line
   Using a line wrench, loosen the pressure line fitting at the power steering pump. Be prepared for residual fluid to drain. Once loosened, finish removing by hand and position the line away from the work area. Cap or plug the line to prevent contamination.
   ⚠Use a line wrench (flare nut wrench) to prevent rounding off the fitting. Standard wrenches may damage the fitting.
   Torque spec

   Pressure Line Fitting32 Nm (24 lb-ft)
3. 3

   Disconnect power steering return hose
   Loosen the hose clamp on the return hose at the pump using a flathead screwdriver or appropriate tool. Carefully pull the return hose off the pump fitting. Allow remaining fluid to drain into the drain pan. Plug the hose to prevent contamination.
4. 4

   Remove power steering pump mounting bolts
   Locate the power steering pump mounting bolts (typically three bolts). Remove all mounting bolts using the appropriate socket. Support the pump as you remove the final bolt to prevent it from falling.
   Torque spec

   Pump Mounting Bolts26 Nm (19 lb-ft)
5. 5

   Remove power steering pump from vehicle
   Carefully maneuver the power steering pump out of the engine bay. Tilt and rotate as necessary to clear surrounding components. Place the pump on a clean work surface with the pulley facing up. Wipe away any external fluid or debris.
6. 6

   Remove power steering pump pulley
   Install the power steering pulley puller tool onto the pulley according to the tool manufacturer's instructions. The puller must engage the pulley securely without contacting the pump shaft. Slowly tighten the puller's center bolt to draw the pulley off the shaft. The pulley should slide off smoothly with even pressure.
   ⚠️Never use impact tools, hammers, or pry bars on the pulley or pump shaft. This will cause internal pump damage requiring pump replacement.
7. 7

   Install new power steering pump pulley
   Position the new pulley onto the pump shaft, ensuring it is aligned straight and seated on the shaft properly. Using the power steering pulley installer tool, press the pulley onto the shaft. The pulley should be flush with the end of the shaft when fully seated. Install slowly and check alignment frequently to ensure the pulley goes on straight.
   ⚠The pulley must be pressed on evenly to avoid cocking it on the shaft. An improperly installed pulley will cause belt misalignment and premature wear.
8. 8

   Reinstall power steering pump
   Position the pump back into its mounting location in the engine bay. Thread all mounting bolts by hand first to ensure proper alignment. Once all bolts are started, tighten them evenly to the specified torque in a star pattern.
   Torque spec

   Pump Mounting Bolts26 Nm (19 lb-ft)
9. 9

   Reconnect power steering lines
   Install new O-rings on the pressure line fitting (lubricate lightly with clean power steering fluid). Thread the pressure line fitting into the pump by hand to avoid cross-threading, then tighten to specification using a line wrench. Reconnect the return hose to the pump fitting and secure with the hose clamp.
   ⚠Always use new O-rings when reconnecting pressure fittings. Reused O-rings may leak.
   Torque spec

   Pressure Line Fitting32 Nm (24 lb-ft)
10. 10

    Reinstall serpentine belt
    Route the serpentine belt around all pulleys according to the belt routing diagram, leaving the tensioner for last. Rotate the tensioner clockwise and slip the belt onto the tensioner pulley. Slowly release the tensioner to apply proper tension to the belt. Verify the belt is properly seated in all pulley grooves.
11. 11

    Fill and bleed power steering system
    Fill the power steering reservoir to the COLD MAX line with Kia PSF-4 fluid. Start the engine and allow it to idle. Turn the steering wheel slowly lock-to-lock several times without holding at full lock. Check fluid level and add as needed. Continue turning the wheel until no air bubbles appear in the reservoir and the fluid level stabilizes. Top off to the appropriate level mark.

Reassembly

1. Ensure all power steering line connections are tight and not leaking
2. Verify serpentine belt is properly routed and tensioned
3. Confirm power steering reservoir is filled to proper level with Kia PSF-4 fluid

Verification

• Start the engine and verify no leaks from power steering pump or line connections
• Turn steering wheel lock-to-lock while stationary to verify smooth operation with no noise
• Check power steering fluid level after test and top off if necessary
• Test drive vehicle and verify normal power steering assist function
• Inspect serpentine belt alignment on all pulleys including the new power steering pump pulley

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