REMOVAL & INSTALLATION
- Remove the air cleaner, air pump and belt.
- Remove the reservoir filler extension and plug the hole with a clean rag.
- From under the car, loosen one pump adjusting bolt.
- Remove one pump-to-bracket mounting bolt and disconnect the fluid return line. Be prepared to catch any spilled fluid in a suitable container.
- From above the car, loosen the adjusting bolt.
- Loosen the pivot bolt and remove the drive belt.
- Remove the two remaining pump-to-bracket mounting bolts.
- Remove the pump by passing the pulley end through the adjusting bracket opening.
- Remove the pressure hose from the pump.
- From beneath the car, attach the pressure hose to the pump.
- Pass the pulley through the opening in the adjusting bracket.
- Install the mounting bolts and tighten to 30-45 ft. Lbs. (41-61 Nm).
- Make sure the air pump belt is on the inner power steering pump pulley groove.
- Install the power steering pump belt. Insert a 1 / 2 inch drive socket wrench handle into the square hole at the bottom of the bracket to obtain the proper belt tension.
- Tighten all the bolts to 30-45 ft. Lbs. (41-61 Nm).
Do not pry on the pump or any of the surrounding aluminum parts or brackets.
- Attach the return line to the pump.
- Remove the rag and install the reservoir filler neck extension.
- Install the air pump and the air cleaner.
- Fill the pump with fluid and check for proper operation.
- Disconnect the negative battery cable.
- Remove the air cleaner, thermactor air pump and belt.
- Remove the reservoir filler extension and cover the hole to prevent dirt from entering.
- If equipped with a remote reservoir, remove the reservoir supply hose at the pump, drain the fluid and plug or cap the opening at the pump to prevent entry of contaminants during removal.
- From under the vehicle, loosen one pump adjusting bolt and one pump-to-bracket mounting bolt
- Disconnect the fluid return line.
- From above the vehicle, loosen one adjusting bolt and the pivot bolt.
- Remove the drive belt and the two remaining pump-to-bracket mounting bolts.
- Remove the pump by passing the pulley through the adjusting bracket opening.
- Remove the pressure hose from the pump assembly.
- From under the vehicle, connect the pressure hose to the pump. Pass the pulley through the opening in the adjusting bracket.
- Install the mounting bolts and tighten to 30-45 ft. lbs. (40-62 Nm).
- If applicable, make sure the air pump belt is on the inner power steering pump pulley groove. Install the power steering pump belt and adjust.
- Tighten all bolts to 30-45 ft. lbs. (40-62 Nm).
When adjusting belt tension, never pry on the pump or surrounding aluminum parts or brackets.
- If not equipped with a remote reservoir, install the return line to the pump.
- From above the vehicle, install the reservoir filler neck extension, if applicable.
- Install the air cleaner.
- If applicable, install the remote reservoir supply to the pump.
- Fill pump or remote reservoir with fluid and check operation.
- Remove the drive belts.
- On air conditioned models, remove the alternator.
- Remove both braces from the support bracket on air conditioned models.
- Disconnect the power steering fluid lines and drain the fluid into a suitable container.
- Remove the four bracket mounting bolts and remove the pump and bracket assembly.
- The pulley must be removed before the pump can be separated from the mounting bracket. Tool T65P-3A733-C or equivalent is required to remove the pulley. Hold the small hex head of the tool and rotate the nut counterclockwise to remove the pulley.
- Remove the pump from the bracket if required.
- If removed, install the pump on the bracket.
- Place the pulley on the pump shaft and install tool T65P-3A733-C or equivalent. Small diameter threads 3 / 8 -16 on the tool should be fully engaged in the pump shaft.
- Hold the pump and rotate the tool nut clockwise to install the pulley on the shaft. The pulley face must be flush within 0.010 inch (0.25mm) of the end of the pump shaft. Do not apply in and out pressure on shaft. Pressure will damage internal thrust areas.
- Remove the tool and install the support bracket with the pump on the engine.
- Attach the power steering lines.
- On air conditioned models, install the alternator.
- Install and adjust the drive belts.
- Fill the pump with fluid and check for proper pump operation.
If air bubbles are present in the power steering fluid, bleed the system by performing the following:
- Fill the reservoir to the proper level.
- Operate the engine until it reaches normal operating temperature.
- Turn the steering wheel all the way to the left then all the way to the right several times. Do not hold the steering wheel in the far left or far right position stops.
- Check the fluid level and recheck the fluid for the presence of trapped air. If it is apparent that air is still in the system, fabricate or obtain a vacuum tester and purge the system as follows:
- Remove the pump dipstick cap assembly.
- Check and fill the pump reservoir with fluid to the COLD FULL mark on the dipstick.
- Disconnect the ignition wire and raise the front of the vehicle and support safely.
- Crank the engine with the starter and check the fluid level. Do not turn the steering wheel at this time.
- Fill the pump reservoir to the COLD FULL mark on the dipstick. Crank the engine with the starter while cycling the steering wheel lock-to-lock. Check the fluid level.
- Tightly insert a suitable size rubber stopper and air evacuator pump into the reservoir fill neck. Connect the ignition coil wire.
- With the engine idling, apply a 15 in. Hg (50.6 kPa) vacuum to the reservoir for three minutes. As air is purged from the system, the vacuum will drop off. Maintain the vacuum on the system as required throughout the three minutes.
- Remove the vacuum source. Fill the reservoir to the COLD FULL mark on the dipstick.
- With the engine idling, re-apply 15 in. Hg (50.6 kPa) vacuum source to the reservoir. Slowly cycle the steering wheel to lock-to-lock stops for approximately five minutes. Do not hold the steering wheel on the stops during cycling. Maintain the vacuum as required.
- Release the vacuum and disconnect the vacuum source. Add fluid, as required.
- Start the engine and cycle the wheel slowly and check for leaks at all connections.
- Lower the front wheels.
- In cases of severe aeration, repeat the procedure.
See Figures 1 and 2