Installation Procedure:

NOTE: For 88/89 MY vehicles, do steps 1 and 2. For 1990 MY vehicles, do step 2 only.


CAUTION: Extreme care must be taken to prevent system contamination. Do not allow any dirt or other debris to enter hoses or the valve block assembly during these operations.


Step 1: Replacement of Pressure Relief Valve (1988/89 MY vehicles):

Determine if hose CCC2637 and a new pressure relief valve has been installed, (fig. 1). If a new valve has been installed, proceed to step. 2. If the valve has not been replaced, proceed as follows:

^ Remove the bolt securing the high pressure hose to the valve block mounting bracket. To gain access to the valve block assembly, reposition the high pressure/A/C hose assembly and secure using string.

^ Using a suitable cleaning fluid, clean the relief valve face and area around the valve block.

^ Position an open ended wrench across the valve block (position the jaws over the "cast on" "Girling" insignia).

FIG. 1:

^ With the aid of an assistant applying counterforce via the open ended wrench, use tool JD 176 and remove the pressure relief valve from the valve block.


NOTE: Service Tool JD 176 (Fig. 1 C) should be seated firmly against the face of the pressure relief valve during the removal procedure.

^ Determine that sealing rings are installed on the new relief valve (CCC 3832). Using JD 176, install the relief valve into the valve block. Tighten to 20-24 N-m. (15-18 ft.lbs.), holding the valve block steady with an open ended wrench.

^ Install the high pressure hose and the A/C hose assembly.

^ Start the engine and check the power hydraulic system for leaks. Check/top-up the fluid level in the power hydraulic fluid reservoir.

Step 2:. Replace the ride level sensor (on vehicles up to VIN 617977):

Check the sensor part number found on the front upper section of the ride level sensor case. If part number is DBC 6768 or DBC 6170, no further action is necessary. If any other part number is found, replace the ride level sensor. Refer to the 1990 MY Sedan Range Repair Manual, section 66, page 66-6 for installation procedure.