How to Replace the Power Steering Oil Cooler in a Mercruiser Alpha 1

The power steering oil cooler is incorporated into the pump body in the Generation 1 Mercruiser Alpha sterndrive. This means that replacing the oil cooler is no more difficult than removing the belt from the power steering pump's pulley, removing the pump, installing a new body and oil cooler and reinstalling the whole kit and caboodle. If undertaken as part of winter maintenance, you get the chance to inspect the pump's critical internal parts as you replace the cooler.

Things You'll Need

  • Drain pan
  • Phillips screwdriver
  • Tape
  • 3/4-inch open-end wrench
  • 9/16-inch socket
  • Ratchet
  • Power steering pump replacement kit
  • Foot-pound torque wrench
  • Mercruiser Quicksilver Power Trim and Steering Fluid
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Instructions

  1. Out With the Old

    • 1

      Place a drain pan near the work area to accept the oil from the pump and oil cooler.

    • 2

      Loosen the hose clamps holding the power steering pump hoses to the pump, using a Phillips screwdriver. Tag the hoses with tape to indicate the orifice from which they are removed.

    • 3

      Loosen the power steering pump bolts -- using a 3/4-inch open-end wrench -- that hold the pump to the power steering pump bracket, slackening the pump belt. Remove the pump belt from the pulley and lift the pump and oil cooler away from the bracket.

    • 4

      Invert the pump over the drain pan and allow the oil to drain from the pump and oil cooler.

    • 5

      Remove the pump fitting assembly, using a 9/16-inch socket and ratchet. Remove the control valve assembly, the flow spring and the O-rings from the pump and oil cooler body. Inspect the control valve assembly and the fitting assembly.

    In With the New

    • 6

      Install new O-rings and a new flow spring, found in the power steering pump replacement kit, to the new pump body and oil cooler. Push the control valve assembly through the flow spring and O-rings and reinstall the fitting assembly. Torque the fitting assembly to 35 foot-pounds with a foot-pound torque wrench.

    • 7

      Install the pump and oil cooler into the pump mounting bracket. Install the pump belt to the pump’s pulley.

    • 8

      Tighten the power steering pump bolts to 35 foot-pounds. Reattach the power steering hoses to the pump’s orifices from which you removed them.

    • 9

      Remove the filler cap from the pump body and add oil to the system. Screw the filler cap and dipstick back into the pump body, just until snug.

    • 10

      Remove the cap and dipstick. The oil level should rest on the crosshatched portion of the dipstick.