I just put in a new power steering pump and a few miles Down the road I start hearing a horrible knocking sound from the engine. It gets louder and faster the more I step on the throttle. I looked at the engine and couldn't figure out where the noise was coming from. Today I was driving to work and suddenly I lost the heater and power steering and warning lights started lighting up. I immediately knew I lost the belt. I got off the freeway and headed for my mechanic. I made it to within half a block and Rover died. No alternator no battery right? They tow the truck in and call me and say, the bolts that hold the pulley onto the power steering pump were to long and we're hitting the pump thus making the initial knocking noise. I used the same bolts off the old pulley for the new one. I don't get it. How could they be to long?! The result being the new pump is shot. The pulley holes are now oblong instead of round. And a pulley bolt completely got sheared off! Very costly repair because of a sticking bolt that should have fit properly in the first place!!!

 

Did you install it or the mechanic? Possible you/He put the wrong bolts?

 

The flange on the pump shaft which the pulley bolts to is just pressed onto the end of the shaft. If you got a remanufactured pump, it's possible they installed the flange too far onto the shaft?

A few years ago, my original ps pulley flange walked forward on the shaft about 1/8" causing a very frustrating year long diagnosis for why my belt was squealing. I replaced the belt a few times, along with new idlers and tensioner assembly. It wasn't until my belt finally broke that I realised the steering pulley was out of line with the other pulleys.

 

Uh no. The bolts were left loose and the pulley made a knocking noise. then the bolts fell out and the belt flew off.

 

If the holes are oblong now, then most likely the pump was loose and flopping around.

 

Does the RAVE say to replace the bolts like it usually does?

 

I think they're on to something.

 

I did the job and used the original mfg bolts. Now after $1000.00 having a new ps pump installed by a mechanic the engine has a knock and it continuously overheats. (The coolant keeps bubbling out). The mechanic is telling me I now need a new engine. I had it towed to a friends mechanic for a second opinion before I install a whole new engine. If it comes to that where can I get a refurbished engine for a 2003 DII?