I just finished replacing my D1 power steering pump with the Chevy S10 one, and while it wasn't a walk in the park (and any of you that said it took "about an hour" are much better mechanic than I am, obviously) it was doable.
Here is some supplemental information all in one place for the next person set on doing this swap:
Advance Auto Parts part number for Cardone PS pump, as of 10/2014: 3790436 (Part # 20-874 works too). $56 +$15core charge.
If Napa is closer to you, part number PS 385168 (1988 Chevy S10 2.5L) $56, and $27 core charge also is available.
Dayco molded heater hose to replace bottom hose due to difference in angle: Advance Auto Parts 87848 (or 10235686) -$21.99. About 11" from the long side will need to be cut off.
Gates Micro-V Serpentine belt (if you haven't replaced it yet, might as well do it now): O'Reilly Auto Parts p/n K070882 (15/16"x88-3/4"OC)- $39.99
Wrenching specs:
tensioner for serpentine belt: 15mm. Long mechanic's wrench works best. Turn wrench CLOCKWISE to release tension and remove the belt.
Bolts attaching PS bracket/shroud to block: 13mm. There are 3 of them. The head of the upper left one was pretty stripped on mine and I ended up replacing it. If you need to do the same, Advance Auto Parts has a Dorman cap screw/hex head/Grade 5 that is an exact fit (3/8"-16 x 2-3/4"). It will require a 14mm wrench to reinstall. Note: all 3 bolts are different lengths- this one will only work for the upper left.
Bolts attaching PS pump to the inside of the bracket/shroud- 10mm. There are two of them.
Bolts attaching PS pulley to shaft mount assembly: 10mm. There are three of them. If you need to replace them, they are M8x1.25x12mm. Not many places had that size in stock, so M8x25x16mm with two M8 washers per bolt works just as well.
Nut holding the flared fitting from the PS hose that you do NOT need to replace: 16mm.
While it was easy to pull the pulley off the shaft of the LR pump using the harmonic balance puller from Advance Auto Parts (p/n 648616- $120 deposit on tool rental), it was a b*tch to try to put the pulley on the new pump. A mechanic around the corner from me pressed it on in about 10 minutes and didn't want to charge me anything. (I gave him $20 and he was really appreciative- I need to get a relationship with a local mechanic, anyway.)
Hope this helps someone else tackle this job.
Here is some supplemental information all in one place for the next person set on doing this swap:
Advance Auto Parts part number for Cardone PS pump, as of 10/2014: 3790436 (Part # 20-874 works too). $56 +$15core charge.
If Napa is closer to you, part number PS 385168 (1988 Chevy S10 2.5L) $56, and $27 core charge also is available.
Dayco molded heater hose to replace bottom hose due to difference in angle: Advance Auto Parts 87848 (or 10235686) -$21.99. About 11" from the long side will need to be cut off.
Gates Micro-V Serpentine belt (if you haven't replaced it yet, might as well do it now): O'Reilly Auto Parts p/n K070882 (15/16"x88-3/4"OC)- $39.99
Wrenching specs:
tensioner for serpentine belt: 15mm. Long mechanic's wrench works best. Turn wrench CLOCKWISE to release tension and remove the belt.
Bolts attaching PS bracket/shroud to block: 13mm. There are 3 of them. The head of the upper left one was pretty stripped on mine and I ended up replacing it. If you need to do the same, Advance Auto Parts has a Dorman cap screw/hex head/Grade 5 that is an exact fit (3/8"-16 x 2-3/4"). It will require a 14mm wrench to reinstall. Note: all 3 bolts are different lengths- this one will only work for the upper left.
Bolts attaching PS pump to the inside of the bracket/shroud- 10mm. There are two of them.
Bolts attaching PS pulley to shaft mount assembly: 10mm. There are three of them. If you need to replace them, they are M8x1.25x12mm. Not many places had that size in stock, so M8x25x16mm with two M8 washers per bolt works just as well.
Nut holding the flared fitting from the PS hose that you do NOT need to replace: 16mm.
While it was easy to pull the pulley off the shaft of the LR pump using the harmonic balance puller from Advance Auto Parts (p/n 648616- $120 deposit on tool rental), it was a b*tch to try to put the pulley on the new pump. A mechanic around the corner from me pressed it on in about 10 minutes and didn't want to charge me anything. (I gave him $20 and he was really appreciative- I need to get a relationship with a local mechanic, anyway.)
Hope this helps someone else tackle this job.