[trublustu]

Hi all...

I have a y2k 1.7 track car which is my rolling project.
I am always looking for more power and less weight

.A good few years ago I drove a 7.5 tonner with no power steering. In tight spaces it was murder, but on the road it was fine.


Now I have already junked the A/C rad & pipes, I think binning the pump, plus PAS pump and pipes i will take out 4-5kg and also get rid of the 1.9M serpentine belt and replace it with a 1M one with two less pulleys and a smoother route. Which might even give me a BHP or two!


I have a couple of snaps of what im trying to achieve, but would like some advice from anyone who has first hand experience.


As I do the job Ill record a photo story for you all ;-)

[trublustu]

Well heres what I have so far.

Most 1.7 pumas have PAS & A/C, great for going to the superemarket in summer, as much use as a chocolate teapot on a track car.


To remove the enormous belt and both pumps is a challenge.
This is how the belt is routed.


Ive never seen a belt make so many tight turns, must sap the power...
Not like this set up....


Here is how the belt runs with the various options..

[trublustu]

I have sourced the correct belt and bought a whole 1.25 mk4 Fiesta Encore for the Adjuster which replaces the PAS pump/tensioner.
You need this part as the original is smaller and in the wrong place..

Has anyone tried this mod and are there any pitfalls (rack ratios etc)

I hope to be doing this at the weekend so welcome any advice...

[Turby]

We have done something similar on our race car. AC gone entirely, PAS replaced with Electro-hydraulic setup from a Saxo into std puma rack. PAS rack is 2.25 turns lock to lock and non pas rack is something like 4+ turns lock to lock. Never found a good setup with PAS rack and no pump - far too much kick back.

At least we can turn the PAS pump on / off when we need to and it only pulls current when turning (more on full lock than slight lock)

[trublustu]

Hello Turby, thanks for the info..
I wondered about the rack ratios and dont fancy a fiestas rack if its ratio is so much lower.

What do you mean by kick-back?

[Turby]

mmm kick-back... its any deflection from front tyres through to the steering wheel, eg pot holes, cat'e eyes, white lines, drains, rumble strips, kerbs at race circuits, undulations in the tarmac etc etc. The more compliance you have the less kick back you will feel. With no PAS pump you wont have any hydraulic damping.

You could try the PAS rack without the PAS pump and see how you get on.

[trublustu]

Well, as this is purely a track animal I could live with this kind of feedback overload.


If it turns out to be undriveable, I will go for a fiesta rack, possibly re-worked with a better ratio.

I believe I would need to do a spot of plumbing to ensure the power rack does have some oil left for lubrication.

My Mk5 transit was manual steering and you really knew if you clipped a kerb etc, much less feedback now ive put a power rack but 3 point turns are a doddle...

[plowy]

Interesting....I am about to embark on my AC pump removal this weekend on my track car but reading your post I'm thinking I like the idea of the PAS removal also,,,to clarify you replaced the original tensioner with an item from a Mk4 1.25 yes,,?,,,,was this a bolt on fit ment..??...also I'm a bit green with the PAS removal so is it possible to remove the pump and associated pipe work but retain the same rack...??

[trublustu]

Hi Plowy.

The tensioner on the PAS + AC vehicle is mounted to the same plate as the PAS pump.
To do this mod you need the tensioner off any zetec-s engine which has only one or none of the options. see third pic.
It is a straight swap, not sure how fiddly itll be, but it was a sod to get off (i need a stud extractor!)


The PAS pump then re-mounts where the AC pump was. see third pic. I assume its a straight fit.


Youll need a new belt, if you want to keep PAS its about 1730mm (guess) to get rid of both its a 1080mm belt (another guess mine isnt at home..) just shop for the fiesta equivalent.


The PAS rack will work fine on its own (you have to do a small mod to keep it lubricated), but as turby kindly pointed out the rack is quicker than a standard non PAS rack and can be harsh.
Ill find out at weekend...


I hope this is helpful. Stu..

[plowy]

Why remount the PAS pump..???

[trublustu]

Its so you can re-route the belt, with nothing there it would want to go straight through the water pump pulley!

Here is a pic of the tensioner from the non PAS/AC engine




Although...

Looking at the pics i cant see why you couldnt just re-route the belt over the pump and use your PAS and its tensioner.
The tensioner might not keep the belt tight enough.
Dont know where you would get a belt either....

This post has been edited by trublustu: 25 January 2014 - 04:16 PM

[Ian G]

That tensioner looks the same as the non-air con Puma one.

You can't re-mount the PAS pic if you're not plumbing it - it won't be lubricated.

[trublustu]

Hi Ian,

I do believe that tensioner is used on PAS only and AC only options as well as neither.
I know about the PAS pump needing to be plumbed in, I figure the fluid lines will be different in the alternative mounting position too.

Not as straight forward as youd think.

My aim is to remove both and work out a way of keeping some (lubrication) oil in the rack.

[Ian G]

Yeah the pipes are different also on the non-AC cars.

If you run without the pump, lubrication shouldn't be an issue. So long as there's some residual fluid in the rack and you cap the connectors you should be OK.

[trublustu]

Would capping the connectors not give me back pressure inside the rack?


I do recall reading a guide which suggested putting a link pipe between the two hydraulic connectors for oil to freely flow between both sides of the PAS piston.

It wouldnt be under pressure so im sure a simple hose would suffice (I may end up with a manual rack anyway, if the ratio is too quick)

[plowy]

Where did you get your belt,,,????... I managed to get a tensioner from a non AC car yesterday so have all I need to remove AC & PAS...

[trublustu]

Good find plowy,


Ive been rained off this weekend, its horrible out there (I must buy that gazebo!)
I dont fancy getting all technical while im shivering. so no updates on the tensioner yet.

Im just gonna give my shock absorber top mounts some attention (did Ford build them loose?)

As for the belt, any auto factor should have one , the exact size is 6PK1181 (6 ribs & 1181mm long) just ask for the one to fit a fiesta with no options..