REMOVAL & INSTALLATION
2.0L Diesel Engine
- 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 remove before the pump can be separated from the mounting bracket. Tool T65P-3A733-C or equivalent is required to remove and install the drive pulley.
- Install the pump and mounting bracket assembly using the 4 mounting bolts.
- Connect the power steering fluid lines, and fill with clean fluid.
- Install the braces if vehicle is equipped with A/C.
- Position and secure the alternator if equipped with A/C.
- Connect the drive belt and tension to specification.
- Start vehicle, and check for air bubbles. Bleed if necessary.
- Road test the vehicle.
- 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 EFI and 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 1 pump adjusting bolt. Remove 1 pump to bracket mounting bolt and disconnect the fluid return line.
- From above the vehicle, loosen 1 adjusting bolt and the pivot bolt. Remove the drive belt and the 2 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 remote reservoir supply to pump on EFI/remote vehicles.
- Fill pump or remote reservoir with fluid and check operation.
- Start vehicle and check for air in the fluid. Bleed if necessary.
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 the fluid reaches normal operating temperature (165-175°F).
- 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 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 vacuum to the reservoir for 3 minutes. As air is purged from the system, the vacuum will drop off. Maintain the vacuum on the system as required throughout the 3 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 vacuum source to the reservoir. Slowly cycle the steering wheel to lock-to-lock stops for approximately 5 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.
- Road test the vehicle.