PS pump / pulley / tensioner noise

[ToSi]

Got a good scare last weekend as I was pulling into the garage after a day of driving - heard what sounded like a timing chain knocking around from a failed tensioner or guide, dull metallic knocking somewhere from the front of the engine. Fearing the worst, I pulled the oil filter only to find nothing unusual. Removed both engine access panels, started car, & began poking around. Tough to pin point - seemed to be coming from the area between the crank damper & power steering pump. Next I removed the accessory belt & started the engine. NO noise - pleasantly relieved. Pulleys seem OK, PS pump has a noticable metallic clunk when turning the pulley back & forth by hand - I assume this is the problem. PS reservoir was about 1/4" low, added fluid hoping it was just the pump cavitating (a stretch, I know) & put the belt back on - still makes noise.

Was hoping for some feedback before I order a new pump. Is this somewhat common? Anything else to replace while I'm at it? Belt looks perfect, tensioner feels good, upper idler pulley has a couple degrees of wobble - is this a sign of wear or intentional to account for belt alignment?

Car is a '97 w/ 42k otherwise trouble-free miles.

Thank you!

[ToSi]

Anyone replaced the pump with the engine installed in the car? Took another look at it today and it doesn't look fun. Lots of stuff in the way - a/c compressor, intake..

[Tool Pants]

I have never done it. It does not look too hard to replace in the shop manual. You break the 3 bolts loose for the puley, then remove the belt, then put the top in the extreme service position, then the throttle body, and some other steps. The shop manual usually has you taking more steps and taking more things apart then are really necessary. I would have to ask Peter if there are any tricks

When we replace the serpentine belt I always check the pulleys because the bearings are known to go bad. I don't think you should have any play in an idler pulley. I can't remember how the p/s pulley is supposed to feel when you rotate it.

If you are sure it is the p/s pump then PM your fax number.

I would take the rear service cover off again and listen with a mechanics stethoscope before you pull the pump.

[ToSi]

Thanks for the reply- I agree, rather change the pulley than the pump. I'll listen again to verify but the pump doesn't feel right. Looks like a pain in the car, there's no clear access to the bolts mounting the pump & the a/c compressor looks like it mounts to the PS bracket assembly. PM'd a fax #, appreciate your help.

Also found today that my service manual CD is speckled w/ data errors that prevents me from opening the running gear chapter (group 4) - argh!! Anyone willing to make a copy to share? Willing to barter for beer :-)

[ToSi]

Just a (late) follow up for the archives - ended up being the water pump, not sure how I missed it in the initial inspection. Pulley had severe wobble & was beginning to drip - the undertray caught the fluid, hence no puddle under the car.

Replacement wasn't too bad. Disconnect hoses, use clamping pliers to prevent draining the entire cooling system. Pump removal & installation is through the access panel behind passenger seat. Only "trick" is to cut the water pump section of the gasket free from the water inlet / t-stat housing portion & only replace that part.. otherwise you need to remove the pump inlet housing which is hindered by the front engine mount since they technically share a gasket - self explanatory when looking at the parts but basically the "gasket" is really 2 connected gaskets that serve both the pump & inlet. No need to remove the inlet to replace the pump.

Aside from the typical difficulty of getting under the car, the entire project is very DIY'able. Bleeding / burping the system is the hardest part of the operation (needed to add ~ 1.5 gallons)..

Thanks-

[adsach]

...Aside from the typical difficulty of getting under the car, the entire project is very DIY'able...

<{POST_SNAPBACK}>

Never having done this, what part of the job required going under the car?

Did you take the seats out, or was there enough room to do the job comfortably with them in?

[Richie_007_1968]

What year and how many miles on your machine? I'm at the 100k myself and am wondering what is around the corner.... Any known 100k issues?