I have spent the better part of the last four days working on my car. I have never thought that mechanical work was easy, and now I definitely have a renewed respect for anyone who does this for a living.
Thursday on my way to work, the pulley on the power steering pump on my car finally gave way. It was only a matter of time. The power steering hadn't worked in months, I guess the bearings finally disintegrated, and then the shaft seized up, shearing the pulley clean off. The battery light came on due to the alternator no longer functioning (it is powered by the same belt that powers the power steering) and fortunately I was able to limp home on battery power. None of this is the worst part though...
I decided to attempt to replace the power steering myself. This required removing the alternator, and then removing what was left of the power steering pump. I had replaced the alternator before, so I was familiar with how to remove it, and was well aware of how much it sucks to have to do so. The power steering pump was easy enough to remove, as the pulley was no longer attached to it.
Once everything was removed, I began the work of acquiring new parts and putting things back together. First up was the power steering pump. This had to be bolted back on sans pulley because there is not enough room to maneuver it into position and bolt it on with the pulley in place. Attaching the pulley was difficult because there is very little clearance between the wheel well and where the pulley bolts on, but I was able to get this done after a few tries.
After getting the power steering pump attached, pulley and all, I discovered that the belt itself was damaged and needed to be replaced. Routing the belt through all of the pulleys, the tensioner and the idler that is between the power steering pulley and air conditioner compressor pulley was an absolute nightmare, especially after having forgotten about the air conditioner compressor pulley on the first try, but after about 30 minutes I managed to get it in place.
Now for the alternator. There are two bolts that hold the alternator on, one of them is in a nearly impossible to reach place, and it takes 20 minutes to take that bolt off, and another 20 at least to put it back on because there is no room to use a ratchet or ratcheting wrench. It has to be done with a conventional wrench. I would rather chew crushed glass than take the alternator off or put it back on, but I ended up doing this a few more times than should have been necessary as you will see below...
I got the alternator on, and the plan was to plug the three connections that go into it
after the alternator was bolted on. This didn't work out because my hands are too big to fit into the very small space I had to work with. So, I ended up having to take the alternator off again just so I could plug these three connectors in. This took forever, but finally I got it done and got the alternator bolted back on, and then pulled the belt over the last pulley.
Now it was time to test drive the car and make sure that everything was working. Power steering still was not working! I forgot to put fluid in the reservoir. I came back from my trip around the block and put fluid in the power steering reservoir. Started the car and prepared to drive around the block again, but instead I heard a popping noise followed by gushing... There are two hoses that need to be connected to the power steering pump, a return hose that goes to the reservoir, and a pressure hose that goes to the rack. I did not plug the pressure hose in, resulting in the pump launching the plastic plug that was inserted into the threaded hose receptacle, and then shooting the power steering fluid all over the garage floor.
I had to take the alternator off once again to get to the power steering pump to see where the pressure hose is suppose to go. Also had to
find the pressure hose. I found the hose, but the threaded end was missing. This was probably broken off in the original pump, which I had already turned in for a core on the new one. I had to make another trip to the auto parts store to get a new pressure hose. After going to three different stores, I found one. I got home and attempted to thread this hose into the power steering pump, again having very little clearance for the two canned hams that I call hands. I was unable to get the thread started on the hose, so at this point I called in reinforcements. My wife, who has considerably smaller hands than I do (lets face it, it would be messed up if she didn't) tried, but also failed to get the hose attached. Back to the drawing board...
I had to take the power steering pump back off. First the pulley, then the pump itself. I got the pump off and then threaded the hose in. To my relief, it was the correct hose. I had some doubts because it was an aftermarket part, and it didn't look exactly like the one that came off of the car. With the hose attached I attempted to put the pump back on, but now I could not maneuver it back into place (it was nearly impossible without the hose attached) and so this is where I gave up for the moment. The car still sits in the garage in pieces, and if I ever get myself out of this one, I promise to never again attempt to fix anything that does not have a keyboard attached to it. :-)
Update: 10/22/2009
I was able to get the car put back together last night. As an added bonus, it actually works. A couple of test drives around the block seem to indicate success. I need to go out and look under the car this evening to make sure nothing is leaking. Next time I will either take the car somewhere to be repaired, or take it out back behind the shed and put it out of its (and my) misery.