Ford Falcon. Manual — part 93

211-02-25 Power

Steering 211-02-25

REMOVAL AND INSTALLATION (Continued)

3. Install new belt over pulleys. Ensure that all

Drive Belt (I6)

V-grooves make proper contact with the pulley as

shown in figure.

NOTE: Vehicles are equipped with a V-ribbed

serpentine accessory drive belt and automatic

tensioner. Replacement belts should be of the same

type as originally installed.

NOTE: Automatic belt tensioners are spring loaded

devices which set and maintain the drive belt tension.

The drive belt should not require tension adjustment

for the life of the belt. Automatic tensioners have belt

wear indicator marks. If the indicator mark is not

between the indicator lines, the belt is worn or an

incorrect belt has been installed.

Item

Description

1

Power steering pump pulley

2

Idle pulley

3

Tensioner pulley

4

A/C Compressor pulley

5

Harmonic Balancer

6

Alternator pulley

7

Water pump pulley

Quick Connect Power Steering Fitting

Item

Description

(I6)

1

Worn belt mark

2

15mm bolt

Seal Replacement

3

New belt mark

If a leak occurs between the tubing and tube nut,

4

Belt wear reference mark

replace the hose assembly. If a leak occurs between

the tube nut and the pump outlet, replace the teflon

NOTE: Conditions requiring belt replacement are rib

seal.

chunkout, severe glazing, frayed cords, etc. Replace

any belt exhibiting one of these conditions.

NOTE: Cracks on the ribbed side of the belt are

considered acceptable. If the belt has chunks missing

from the ribs it should be replaced if two or more

adjacent ribs have lost sections 13 mm (1/2inch) or

longer, or if the missing chunks are creating a noise

or vibration.

Removal and Installation
1. Rotate automatic tensioner clockwise.
2. Remove old belt.

Item

Description

1

Tube nut

2

Snap ring

3

Pump outlet

4

Rubber O-Ring

5

Rubber O-Ring

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211-02-26 Power

Steering 211-02-26

REMOVAL AND INSTALLATION (Continued)

1. Check fitting to determine whether leak is

6. Connect quick connector and tighten to 30 Nm.

between tube and tube nut or between tube nut

The quick connect fitting may disengage if not

and pump outlet.

fully assembled, if the snap ring is missing, or if

the tube nut or the hose end is not machined

2. If leak is between tube nut and pump outlet,

properly.

check to ensure nut is tightened to 30 Nm.

If the fitting disengages, replace the hose

assembly. The fitting is fully engaged only when

CAUTION: DO NOT over-tighten.

the hose will not pull out. To test for positive

3. If leak continues or if leak is between tube and

engagement, the system should be properly filled,

connector, remove line.

the engine started, and the steering wheel cycled

4. Unscrew connector, and inspect and replace

from lock-to-lock. When replacing pressure hose

rubber O-ring seal.

assembly the following parts will be required.

5. The rubber O-ring inside the connector (quick

Pressure hose assy. – Qty 1.

connect fitting) cannot be serviced with this

Quick Connect Fitting – Qty 1.

design. If leak is due to the O-ring, replace the

hose assembly.

Power Steering Lines (I6)

Removal

6. Loosen both clamps on return hoses at the cooler

ends & disconnect hoses.

1. Disconnect pressure & return lines from the

steering gear 7 drain the fluid into a suitable

7. Loosen clamp on return hose at reservoir &

container.

remove hose.

2. Remove the bolt from the securing clamp from the 8. Remove the nuts securing the cooler to the

RH side of the 2B crossmember.

subframe cooler brackets.

3. Remove the bolt from the cooler line securing

9. Remove press & rtn line assy & cooler assy from

clamp from the RH side of 2A crossmember.

vehicle.

4. Remove front bumper lower valance.
5. Disconnect the pressure line from pump.

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211-02-27 Power

Steering 211-02-27

REMOVAL AND INSTALLATION (Continued)

Installation
1. Refit press & rtn line assy & cooler assy to

vehicle.

2. Secure the cooler to the cooler mounting brackets

on the subframe (check that the clearances from

the cooler & side chassis rail are adequate) &

tighten nuts.

3. Secure the bolt from the cooler line securing

clamp to the RH side of the 2A crossmember.

4. Secure the bolt from the press & rtn line assy

clamp to the RH side of the 2B crossmember.

5. Connect pressure & return lines to steering gear

end.

6. Connect both return hoses to cooler ends &

secure both clamps.

7. Connect return hose to resorvoir inlet & secure

clamp.

8. Refit a new quick connect fitting to pump &

connect the pressure line.

9. Refit the front bumper lower valance.
10. Fill with specified Mobil 424 oil or equivalent &

conduct specified bleed procedure.

11. Start vehicle, check for leaks, rectify if necessary.

Power Steering Lines (V8)

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211-02-28 Power

Steering 211-02-28

REMOVAL AND INSTALLATION (Continued)

Removal
1. Disconnect pressure & return lines from the

steering gear & drain the fluid into a suitable

container.

2. Remove the bolt from the securing clamp from the

RH side of the 2B crossmember.

3. Remove the bolt from the cooler line securing

clamp from the RH & LH side of a 2A

crossmember.

4. Remove front bumper lower valance.
5. Disconnect the pressure line from pump.
6. Loosen clamp on return hose at pump &

disconnect hoses.

7. Loosen both clamps on return hoses at the cooler

ends & disconnect hoses.

8. Loosen both clamps on return hoses at resorvoir

& remove hoses.

9. Remove the nuts securing the cooler to the

subframe cooler brackets.

10. Remove press & return line assembly & cooler

assembly from vehicle.

Installation
NOTE: When connecting a fitting with a seal ring, the

ring must be replaced, using the seal replacer special

tool.

1. Refit press & return line assembly & cooler

assembly to vehicle.

2. Secure the cooler to the cooler mounting brackets

on the subframe (check that the clearances from

the cooler side chassis rail condenser are

adequate) & tighten nuts.

3. Secure the bolts from the cooler line securing

clamp to the LH & RH side of the 2A

crossmember.

4. Secure the bolt from the press & return line assy

clamp to the RH side of the 2B crossmember.

5. Connect pressure & return lines to steering gear

end.

6. Connect return hose to pump & secure clamp.
7. Connect both return hoses to cooler ends &

secure both clamps.

8. Connect return hoses to reservoir & secure

clamps.

9. Refit a new quick connect fitting to pump &

connect the pressure line.

10. Refit the front bumper lower valance.
11. Fill with specified Mobil 424 or equivelant &

conduct specified bleed preocedure.

12. Start vehicle, check for leaks, rectify if necessary

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