Isuzu Libro 2.pdf

CAUTION

In order to

reduce the chance

of personal injury and/or

property

damage, carefully

observe

the instructions that follow:

The service manuals of

Isuzu

Motors

America Inc.

are

intended

for use

by professional, qualified technicians.

Attempting

repairs

or

service without the

appropriate

training, tools, and equipment could

cause injury

to you or others.

This

could

also

damage

the

vehicle, or

cause

the

vehicle to operate

improperly.

Proper vehicle

service and repair

are important to the safety of the

service

technician

and

to the safe, reliable

operation

of all motor

vehicles.

If _you

_{need to replace}

a _{part, use}

_the

_same

part number or an equivalent part. Do not use a _{replacement part of lesser quality.}

The service procedures we recommend

and describe in this

service manual

are

effective

methods of performing

service and

repair. Some of

the procedures

require

the

use of tools

that are designed

for specific

purposes.

Accordingly,

any

person

who intends

to use a _{replacement part,} a

_service

_{procedure, or} a

tool that is not

recommended

by Isuzu, must first establish

that there

is _{no jeopardy to} personal safety or

the safe operation

of the vehicle.

This manual

contains various CAUTIONS

and

NOTICES

that you must

observe

carefully in

order to

reduce the risk of

personal

injury during

service

or repair. Improper

service

or

repair

may

damage the vehicle

or render

the

vehicle unsafe.

These

CAUTIONS and

NOTICES

are not

exhaustive. Isuzu can

not

possibly warn of all

the potentially

hazardous

consequences of your failure

to

follow these instructions.

This

manual

covers

service

procedures

to

vehicles that

are equipped with a _Supplemental

Inflatable Restraint (SIR).

Refer to

the

CAUTIONS

in Cautions and Notices and in _Restraints. Refer to SIR component and

wiring

location

views

in Restraints before

performing

a

_service

on or

around

SIR

components

or

wiring.

Failure to

follow these CAUTIONS

could

cause

air bag deployment,

personal

injury, or otherwise unneeded SIR repairs.

In

_order

to help avoid

accidental

air bag deployment

and personal

injury, whenever you

service

a _vehicle

_{that requires}

_{repair of the SIR and another vehicle system,}

_{we recommend}

that you

first repair the

SIR,

then

go

on to the other

system.

New

Style Service Manual Structure

This

new

style service

manual

is

_{constructed with}

the following

10 sections:

0.

General

Information

1.

Heating, Ventilation,

and

Air

Conditioning

(HVAC)

2.

Steering

3. Suspension

4. Driveline

and Axle

5. Brakes

6.

Engine

7. Transmission

8.

Body

and Accessories

9. Restraints

The following

table

gives the

previous service

manual sub-sections

with

the

name

of

the

_new

section

and sub-section. Almost

all of

the

diagnosis

that

_was

in

section

8A

is

_now

_located

in its

_{applicable sub-section.}

Truck

Service Manual

Sub-Section to

Section

and Sub-Section Conversion

Table

Old

Sub-Section

OA OB OC 1A 1B 1D 2A 3A

3B,3B1A,

3B1B

3B3 3C 3D 3E 3F 4A 4B

4C

5 5A 5B 5C

5D

5E 5F 6, 6A 6B 6C 6D — 6F 6H 6J 7A

Old Sub-Section

General Information Maintenance and Lubrication Vibration Diagnosis

Heating and Ventilation Heating, Ventilation, and

Air Conditioning A/C Compressors

Frame and Bumpers Front Wheel Alignment Power Steering

Gear

and

Pump Steering Linkage Front Suspension

Rear

Suspension Tires and Wheels

Steering Columns Propeller Shaft Rear Axle and Differential

Front Drive Axles and Differential

Hydraulic Brakes Master Cylinder Front Disc Brakes

Drum Brakes Hydraulic or Vacuum Booster Antilock Brakes Parking Brake Engine Mechanical Engine Cooling and

Radiator Engine Fuel Engine Electrical Driveability and Emissions

Exhaust System Vacuum Pump Turbocharger Automatic Transmission

New

Section

0 0 0 1 1 1 8 3 2 2 3 3 3 2 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 7

Section Name

General Information General Information General Information HVAC HVAC HVAC

Body and Accessories Suspension Steering Steering Suspension Suspension Suspension Steering Driveline/Axle Driveline/Axle Driveline/Axle Brakes Brakes Brakes Brakes Brakes Brakes Brakes Engine Engine Engine Engine — — Engine Engine Transmission/Transaxle

Sub-Section Name

General Information Maintenance and Lubrication Vibration Diagnosis Heating and Ventilation

(Non A/C) HVAC systems with Air

Conditioning HVAC systems with Air

Conditioning

Frame and Underbody, and Bumpers

Wheel Alignment

Power Steering System Steenng Linkage Front Suspension Rear Suspension Tires and Wheels Steering Wheel and

Column Propeller Shaft Rear Drive Axle Front Wheel Drive Shafts

and Front Drive Axle Hydraulic Brakes Hydraulic Brakes Disc Brakes Drum Brakes Hydraulic Brakes Antilock Brakes Parking _Brake Engine Mechanical Engine Cooling Engine Controls Engine Electrical Engine Controls Exhaust System Vacuum Pump Turbocharger Automatic Transmission and Transmission/Transfer Case Unit Repair Manual

Truck

Service

Manual

Sub-Section

to Section

and Sub-Section

Conversion

Table

(cont'd)

Old

Sub-Section

7B 7C

7D

8B 8C 8D 8E 9A 9B 9E 9F 9J 9K 10A1 10A2 10A3 10A4 10A5 10B

Old Sub-Section

Manual Transmission Clutch Transfer Case Lighting Systems Instrument Panel and

Gages

Chassis Electrical Wipers and Washers

Audio Systems Cruise Control Engine Coolant Heater

Luggage Carrier Supplemental Inflatable

Restraint Remote Keyless Entry

Doors Seats

Stationary Windows Interior Trim

Endgate Cab and Body

Maintenance

New

Section

7 7 4 8 8 8 8 8 8 6 8 9 8 8 8 9 8 8 8 —

Section

Name

Transmission/Transaxle Transmission/Transaxle Driveline/Axle Body and Accessories

Body and Accessories

Body and Accessories Body and Accessories Body and Accessories

Engine

Body and Accessories

Restraints Body and Accessories Body and Accessories Body and Accessories

Restraints Body and Accessories Body and Accessories Body and Accessories

—

Sub-Section

Name

Manual Transmission and

Transmission/Transfer Case Unit Repair Manual

Clutch Transfer Case and Transmission/Transfer Case Unit Repair Manual

Lighting Systems Instrument Panel, Gages

and Console Refer to the Index at the

end of the manual Wiper/Washer Systems Entertainment Cruise Control Engine Cooling Roof Supplemental Inflatable Restraints Keyless Entry Doors Seats Seat Belts Stationary Glass Exterior/Interior Trim

Body Rear End Refer to the Index at the

1998

Medium

Duty

THick

FSR,

FTR,

FVR

Service Manual

Volume

2

This manual provides information on the diagnosis, the service procedures, the adjustments, and the specifications for the 1998 Isuzu Medium Duty Truck.

The technicians who understand the material in _{this manual and} in the appropriate Dealer Service Bulletins better service the vehicle owners.

When this manual refers to a _{brand name,} a _{part number, or} a specific tool, you may use an equivalent product in

place of the recommended item. All information, illustrations and specifications in _{this manual are based} on the latest product information available at the time of publication approval. Isuzu reserves the right to make changes at any time without notice.

Published by

ISUZU

MOTORS

AMERICA, INC.

©1998 ISUZU MOTORS AMERICA, INC. The information cutoff date is 12/1/97.

ALL RIGHTS RESERVED LITHO IN _U.S.A.

No part of this manual may be reproduced, stored in _{any retrieval system, or transmitted} in any form or by any means

(including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of

Table of

Contents

Volume

1

Preface...i Cautions and _Notices...3

General

_{Information...0-1} General Information...0-3 Maintenance and _{Lubrication...0-33} Vibration Diagnosis _{and Correction...0-51} HVAC...1-1 Heating and Ventilation _{(Non-A/C)...1-3} HVAC Systems with A/C -

Manual...1-57

Body and

_{Accessories...8-i}

Lighting Systems...8-7 Wipers/Washer _{Systems...8-103} Entertainment...8-123 Wiring Systems...8-143 Instrument Panel, Gauges and _{Console...8-283} Horns...8-351 Exterior _Trim...8-361 Waterleaks...8-363 Stationary _{Windows...8-365} Bumpers...8-373 Body Front End _...8-377 Doors...8-399 Seats...8-431 Interior Trim...8-441 Plastic Panel Information and _{Repair...8-453} Paint/Coatings...8-455 Frame and _{Underbody...8-463} Collision Repair...8-485

Restraints...9-1

Seat Belts...9-3

Volume

2 Preface... Cautions and Notices...

Steering

_...

Power Steering System

... Steering Linkage (Non-Rack & Pinion). Steering Wheel and Column -

Tilt... ...1 ...3 ...2-1 ...2-3

.2-53

.2-63

Suspension...

Suspension General Diagnosis Wheel _Alignment... Front Suspension... Rear Suspension

... Tires _{and Wheels...} Air _{Suspension...}

Driveline/Axle...

Propeller _Shaft... Rear Drive

Axle... Rear _{Axle Controls...} Brakes... Hydraulic Brakes... Disc _Brakes... Park Brakes ... Air Brakes ... Air Drums... Air _{Compressor...} Antilock Brake System... Air Antilock Brake System _...

Volume

3 Preface...

Cautions and Notices... Engine... Engine Cooling ... Engine Electrical ... Engine Controls - 7.8L... Engine Exhaust... Engine, On-vehicle Service

... Engine _Overhaul... Water _Pump... Fuel System ... Fuel Injection ... Diesel Electrical ...—.. Emission and Electrical Diagnosis _.... Turbocharger...

Transmission/Transaxle...

Manual Transmission - Medium Duty.

Automatic Transmission -

Allison... Clutch... Manual Transmission _Overhaul...

Preface

Table

of Contents

• 1

Cautions and

Notices

Cautions

and

_Notices...3

Definition of Caution, Notice, and Important...3 ABS Handling

Caution...3 Battery Disconnect Caution...

Brake Dust Caution... Brake Fluid Caution

... Clutch Dust Caution

... Fuel _{and EVAP Pipe Caution...} Fuel Gauge Leak Caution

... Fuel Pipe Fitting Caution

... Fuel Storage Caution _... Gasoline/Gasoline _{Vapors Caution...} Moving Parts and Hot Surfaces Caution, Road Test Caution

...

Safety _{Glasses and Compressed} Air Caution

... Safety Goggles and Fuel Caution... Vehicle Lifting Caution

... Window Removal Caution _... Work Stall Test _Caution... Defective Scan Tool Notice

... Fastener _Notice... Fuel Pressure Notice _... Handling ESD _{Sensitive Parts Notice.} Ignition OFF When Disconnecting

Battery Notice

... Nylon Fuel Lines Notice

... PCM and ESD

Notice... Single Cylinder Flooding Notice

...

2 -

Table

of

Contents

Preface

BLANK

Preface

Cautions and

Notices

- 3

Cautions and Notices

Definition

of

Caution,

Notice,

and Important

The diagnosis and repair procedures in the Isuzu Service Manual contain both general and specific Cautions, Notices, and Importants. Isuzu is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle, however, certain procedures may present a hazard

to the technician if _{they are not followed} in the recommended manner. Cautions, Notices, and Importants are elements designed to prevent these hazards, however, not all _{hazards can be foreseen.}

This information is _{placed at strategic locations within}

the service manual. This information is _{designed to}

prevent the following from occurring:

• Serious bodily injury to the technician • Damage to the vehicle

• Unnecessary vehicle repairs

• Unnecessary component replacement • Improper repair or replacement of vehicle

components. Any caution or notice that appears

in _{general information} is _{referenced from} the individual service categories.

CAUTION Defined

When encountering a CAUTION, you will be asked to take a _{necessary action or not to take} a

prohibited action. If a

CAUTION

is not heeded, the following consequences may occur:

• Serious bodily injury to the technician

• Serious bodily injury to other technicians in the

workplace area

• Serious bodily injury to the driver and/or

passenger(s) of the vehicle, if the vehicle has been improperly repaired

NOTICE Defined

Notices call special attention to a _{necessary action} or to a prohibited action. If a NOTICE is _{not heeded,}

the following consequences may occur:

• Damage to the vehicle • Unnecessary vehicle repairs

• Unnecessary component replacement • Improper operation or performance of the

system or component under repair

• Damage to any systems or components which

are dependent upon the proper operation of the system or component under repair

• Improper operation or performance of any

systems or components which are dependent upon the proper operation or performance of the system or component under repair

•

Damage

to fasteners, basic tools, or

special tools

•

The

leakage of coolant, lubricant, or other

vital fluids

1998 - MD-lsuzu

IMPORTANT

Defined

IMPORTANT statements emphasize a _necessary

characteristic of a _{diagnostic or repair procedure.}

IMPORTANT statements are designed to do the following:

• Clarify a procedure

• Present additional information for accomplishing

a _procedure

• Give insight into the

reason or reasons for performing a _procedure in _{the manner}

recommended

• Present information that wilt help to accomplish

a _procedure in a _{more effective manner}

• Present information that gives the technician

the benefit of past experience in accomplishing a _procedure with _{greater ease}

ABS Handling Caution

Caution: Certain

components

in the Antllock

Brake

System (ABS) are

not

Intended to be serviced Individually. Attempting to

remove or

disconnect

certain

system components may

result

In

_personal

injury

and/or improper system

operation. Only those

component

with approved removal

and

installation procedures

should

be

serviced.

Battery

Disconnect

Caution

Caution: Before servicing

any

electrical

component, the Ignition key

must

be In

the OFF

or LOCK

position

and

all

electrical

loads

must be

OFF, _{unless Instructed otherwise} In _these

procedures.

If a _tool

_or

_{equipment could easily}

come

in _{contact with} a _{live exposed electrical}

terminal, also

disconnect

the

negative

battery cable. Failure to follow these precautions may

cause

personal injury and/or

damage

to the vehicle

or

Its

_components.

Brake

Dust Caution

Caution: Avoid taking

the

following actions

when

you

service

wheel

brake parts:

• Do not grind brake linings. • Do not

sand

brake linings.

• Do not

clean wheel brake parts

with _a dry

brush

_{or with compressed}

air.

Some models

or

aftermarket

brake parts may contain

asbestos

fibers

which

can become

airborne

In _{dust. Breathing}

dust

with asbestos fibers may

cause

serious bodily harm. Use a

water-dampened cloth

in

order

to remove

any

dust

on

brake

parts.

Equipment

is available commercially In

_order

to

perform

this

_washing

function.

These wet

methods

prevent

fibers from becoming airborne.

4 -

Cautions and

Notices

Preface

Brake

Fluid Caution

Caution: Brake fluid

may

be irritating to the skin

or

eyes. In

case of

contact,

take

the following actions:

•

_Eye

contact—rinse

eyes

thoroughly

with water.

• Skin

contact—wash skin with soap

and

water.

Clutch Dust

Caution

Caution:

When servicing clutch

parts,

do not

create

dust

by grinding

or sanding

the clutch disc or by

cleaning

parts with a _dry

brush

or with

compressed

air. A

water-dampened

cloth—NOT SOAKED—should be

used. The clutch disc contains asbestos

fibers which

can

become

airborne if

dust

is created during servicing. Breathing

dust

containing asbestos

fibers may

cause serious

bodily harm.

Fuel

and EVAP

Pipe

_Caution

Caution: In

_order

to Reduce the Risk of Fire

and

Personal Injury

observe the

following Items:

•

Replace

all nylon fuel

pipes that

are nicked,

scratched or damaged

during Installation,

Do

Not

attempt

to repair the sections

of

the nylon fuel pipes

• Do Not hammer directly on

the

fuel harness

body

clips

when

installing

new

fuel pipes.

Damage to

the nylon

pipes may

result In a

fuel leak.

• Always

cover

nylon

vapor pipes

with a

wet

towel

before using a

_{torch near}

them. Also, never

expose

the

vehicle to temperatures

higher

than

115°C

_{(239'F) for more than one}

hour,

or more

than

90'C (194'F)

for

any

extended

period.

' Apply a

few

drops

of

clean

engine

oil to the

male

pipe

ends

before connecting

fuel

pipe

fittings. This will

ensure proper

reconnect/on and

prevent

a

_possible

_{fuel leak. (During}

normal operation,

the 0-rings

located In

the

female

connector

will

swell and may

prevent

proper reconnect/on

If

not

lubricated.)

Fuel

Gauge Leak

Caution

Caution: Wrap a _{shop towel around}

_the

_fuel

pressure connection In _{order to reduce the} risk

of

fire and personal injury. The towel will

_{absorb any}

fuel leakage that occurs during

the

connection

of

the fuel pressure gauge. Place

the

towel In _an approved container when the connection of the fuel

pressure

gauge

Is complete.

Fuel Pipe Fitting

Caution

Caution:

Always

apply a

_{few drops of}

_clean

engine

oil

to

the male

pipe

ends before

connecting fuel pipe fittings In

order

to reduce the risk

of

fire

and

personal Injury.

This

will

_{ensure proper reconnect/on and prevent}

a _{possible fuel leak.}

During normal

operation,

the 0-rings located

In the

female connector

will swell

_{and may prevent}

proper reconnect/on

//

not

lubricated.

Fuel

Storage Caution

Caution: Do not drain the fuel into

an open

container.

Never store the

fuel in

_{an open}

container due

to

the

possibility

of

a

_{fire or}

an explosion.

Gasoline/Gasoline Vapors Caution

Caution:

Gasoline or

gasoline vapors are highly

flammable.

A

_{fire could occur}

If

_an

_Ignition

source

Is

present Never

drain

or store gasoline

or

diesel fuel

In an

open

container,

due to the

possibility of fire or

explosion. Have a _dry

chemical

(Class

B)

_{fire extinguisher nearby.}

Moving Parts and Hot Surfaces Caution

Caution:

While working

around a _{running engine,}

avoid

contact

with

moving

parts

and hot surfaces

to

prevent possible bodily

Injury.

Road

Test Caution

Caution: Road

test a

_vehicle

_under

_safe

conditions and while

obeying all _{traffic laws.}

Do

not

attempt any maneuvers

that

_{could jeopardize}

vehicle

control. Failure to

adhere

to

these

precautions

could lead

to serious personal Injury.

Safety

Glasses and Compressed

Air

Caution

Caution: Wear safety glasses

when using

compressed air

in

order

to prevent

eye

Injury.

Safety Goggles and

Fuel

Caution

Caution:

Always wear safety

goggles

when

working with

fuel In

order

to protect

the eyes

from fuel

splash.

Vehicle

Lifting Caution

Caution: To

help

avoid

personal

Injury,

when

a

vehicle

Is on

a _hoist,

_provide

_additional

_support

for the

vehicle at the opposite

end from

which

you

are

removing components. The

additional

support will

reduce

the possibility

of the

vehicle falling off

the

hoist.

When you are removing

major

components from the vehicle while the

vehicle

Is

on

a _hoist,

_chain

_the

_vehicle

_{frame to}

the

hoist pads at the same end from which you

are removing the major

components to prevent tip-off. If

_you

fall to follow these

precautionary

measures,

vehicle

damage, serious

personal

Injury,

_{or death may}

result.

Window Removal Caution

Caution:

When working

with any

type

of

glass,

use approved

safety

glasses

and

gloves

to

reduce the chance of

personal Injury.

1998 -

Preface

Cautions and

Notices

- 5

Work

Stall

Test

Caution

Caution: One or more of the

following guidelines

may

apply

when performing specific required

tests

in

the work

stall:

•

When

a test requires

spinning

the drive

wheels

with the

vehicle jacked

up,

adhere

to

the

following precautions:

- Do not exceed

56 km/h

(35 mph) when

spinning one drive wheel with

the

other drive wheel stopped. This limit is necessary because the speedometer Indicates only one-half the actual vehicle

speed

under these conditions. Personal Injury may result from excessive wheel spinning.

- If all of the

drive wheels

are

spinning

at

the same

speed, do not

exceed

112 km/h (70 mph). Personal

injury may

result

from

excessive

wheel spinning.

- All persons

should

stay

clear of the

rotating

components

and

the

balance

weight areas in

order

to

avoid possible

personal

Injury.

-

When

running an engine In

the

repair stall

for

an

extended

period

of

time,

use

care

not to

overheat the engine and the

transmission.

• When a test

requires

jacking up the

vehicle

and

running with

the

wheels

and

brake rotors removed, adhere

to the following

precautions:

-

Do

not apply

the brake

with

the

brake

rotors removed.

- Do

not place the

transmission in

PARK

with the

drive

wheels

still spinning.

- Turn Off the ignition in

order to stop the

powertrain

components from

spinning.

Defective

Scan

Tool

Notice

Notice: Do not use a _{scan tool} that displays faulty data. Report the scan tool problem to the

manufacturer. Use of a _{faulty scan tool can result} in

misdiagnosis and unnecessary parts replacement.

Fastener

Notice

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking _{compound or sealant are} identified in _the

service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners

in _{order to avoid damage} to parts and systems.

Fuel

Pressure

Notice

Notice: Do not allow the fuel pressure to exceed the specified value because damage to the fuel pressure regulator or the fuel pressure gauge may result.

1998 - MD-lsuzu

Handling

ESD

Sensitive Parts Notice

Notice: Electrostatic discharge (ESD) can damage many solid-state electrical components. ESD susceptible components may or may not be labeled

with the

ESD

symbol. Handle all _electrical

components carefully. Use the following precautions

in order to avoid ESD damage:

Touch a _{metal ground point} in _order to remove your body's static charge before servicing any electronic component; especially after sliding across the vehicle seat.

Do not touch exposed terminals. Terminals may connect to circuits susceptible the _{ESD damage.} Do not allow tools to contact exposed terminals when servicing connectors.

Do not remove components from their protective packaging until _{required to do so.}

Avoid the following actions unless required by the diagnostic procedure:

Jumpering or grounding of the components or connectors.

Connecting test equipment probes to components or connectors. Connect the ground lead first when using test probes.

Ground the protective packaging of any component before opening. Do not rest solid-state components on metal workbenches, or on top of _{TVs, radios, or}

other electrical devices.

ignition

OFF When

Disconnecting

Battery

Notice

Notice: Always turn the ignition

OFF

when

connecting or disconnecting battery cables, battery chargers, or jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.

Nylon

Fuel Lines

Notice

Notice: Do not attempt to straighten the kinked nylon

fuel lines. Replace any kinked nylon fuel feed or return

pipes in _order to prevent damage to the vehicle.

PCM and ESD

Notice

Notice: Do not touch the connector pins or soldered components on the circuit board in _order to prevent possible electrostatic discharge (ESD) damage to the PCM.

Single Cylinder Flooding

Notice

Notice: In order to prevent flooding of a single

cylinder and possible engine damage, relieve the fuel pressure before performing the fuel injector

6 -

Cautions

and Notices

Preface

BLANK

Section

2

Steering

Power Steering

_System...

Specifications... Fastener _{Tightening Specifications...} Diagnostic Information

and

Procedures .

Power Steering System Test _Procedure, Objectionable Hiss ... .2-3 .2-3 .2-3 .2-3 .2-3

.2-5

Rattle or Chuckle Noise in _Steering

_Gear...2-5

Excessive Wheel Kickback or Loose

Steering...2-5 Increase in Effort While Turning

Steering

Wheel...2-6 Poor Return of _{Steering Wheel...2-6} Steering Wheel Surges/Jerks While Turning _..2-6 Steering Effort Hard in Both _{Directions...2-6} Vehicle Leads to

One

Side or the

_Other...2-7

Foaming, Milky-Appearing PS Fluid,

Low in

Level...2-7 Low Oil _{Pressure Due to Restriction} in the

Hose...2-7 Low Oil Pressure Due to Steering _Gear...2-7 Low Oil _{Pressure Due} to Steering _{Pump ...2-8} Groan Noise in _{Steering Pump...2-8} Growl Noise in Steering

Pump...2-8 Rattle or Knock Noise in Steering _Pump...2-9 Swish Noise in _{Steering Pump...2-9}

Whine Noise in Steering

Pump...2-9

Repair

_{Instructions...2-10}

Power Steering _{Pump Replacement...2-10} Power Steering Pump Assemble

(P/S Pump Repair

W/

Air _{Brakes)...2-12} Power Steering Pump Assemble

(P/S _Pump Repair

W/

Hyd _{Brakes)...2-18} Bleeding Power Steering _{System...2-27} Flushing the Power Steering _{System...2-28} Power Steering _{Hose Flushing...2-29} Power Steering Hoses Replacement _...2-31 Power Steering _{Gear Replacement...2-34} Sector Shaft Dust _{Cap Replacement...2-36} Input Shaft Dust _{Cap Replacement ...2-37} Input Shaft Bearing Protector Cap

Replacement...2-40 End Limiters _{Replacement...2-42} Pressure Relief Valve _{Replacement...2-44} Resuction Valve _{Replacement...2-46} Power Steering Reservoir _{Replacement ...2-47} Description

and

_{Operation ...2-51}

Power Steering System Description...2-51

Special Tools and Equipment...2-51 Special

Tools...2-51

Steering

Linkage (Non-Rack

&

_{Pinion)...2-53}

Specifications...2-53 Fastener Tightening _{Specifications...2-53} Repair Instructions...2-53 Steering Linkage Inspection _...2-53 Tie Rod

Replacement...2-54 Steering Arm _{Replacement...2-56} Tie Rod Arm _{Replacement...2-57} Relay Rod Replacement...2-58 Pitman _{Arm Replacement...2-59} Description

and

_{Operation...2-62} Steering Linkage _{Description...2-62} Special Tools and Equipment...2-62

Special

Tools...2-62

Steering

Wheel and Column

-

Tilt...2-63 Specifications...2-63 Fastener Tightening _{Specifications...2-63} Diagnostic

Information

and

Procedures

_...2-63

Lock System Sticks in Start

...2-63 Key Cannot Be Removed in the Off

Lock

Position...2-63 Noise in _Steering

Column...2-63 High Steering Shaft

Effort...2-63 Loose Steering Wheel (Every Other

Tilt

Position)...2-64 Steering _{Wheel Does} Not Lock in Any

Tilt

Position...2-64 Steering _{Wheel Not Returning to Top}

Tilt

Position...2-64 Noise When Tilting Steering _{Column...2-64} Turn Signal Does Not Cancel _...2-64 Repair Instructions...2-65 Ignition Switch _{Replacement ...2-65} Multifunction Turn Signal Lever

Replacement...2-66 Tilt _Lever

Replacement...2-67 Steering _{Wheel Replacement...2-68} Upper Steering Shaft Assembly

Replacement...2-71 Lower Steering Shaft Assembly

Replacement...2-74 Description

and

_{Operation...2-77} Steering Wheel and Column Description...2-77 Special Tools

and

_{Equipment...2-78}

Special

Tools...2-78

2-2 Table of

Contents_________________________________Steering

BLANK

Steering

Power

Steering System 2-3

Power Steering System

Specifications

Fastener Tightening Specifications

Application Cardan Nut

Power Steering _Gear Mounting Nut

Power Steering Pipe Adapter Nut at Bulk Head

Power Steering Pipe Mounting Nut Reservoir Mounting Bolt

Power Steering Pump Hose Adapter Mounting Bolt Pressure Plate Screw

Pump Body Bolt Valve Plug Specification Metric 55N.m 450 N.m 52N.m 22 N.m 40 N.m 52N.m 8 _N.m 54 N.m 54 _N.m English 41 Ibft

330lbft

38 to ft 16 to ft 30 to ft 38 to ft 71 to in 40 to ft 40 to ft

Diagnostic Information

and

Procedures

Power Steering System Test Procedure

Tools

Required

J

_26487-C

_{Power Steering Analyzer}

227945

The J _{26487-C tool set includes} the following components:

. The

0-3000

psi pressure gage

. The

0-10

gpm (gallons per minute) flow meter . The Gate Valve

• Hoses

• Hose Adapters

Important:

The

steering gear has end limiter valves (end limiters) which provide an increase in steering

effort at a point within 1/3 turn of the axle stop contact. This is _{normal operation.}

1. Place a _{container under the power steering}

hoses at the power steering hose bulk head in

order to catch the fluid _{when disconnecting or}

connecting the hoses.

Clean the surface of the hoses before disconnecting the _hoses.

2. Use the J-42971 (Hydraulic Line Seperator) to disconnect the pressure hose snap-to-connect fittings _{at the power steering hose bulk head.} Important: Lubricate the tool end in _{power steering}

fluid _{to ensure smooth} engagement with the quik disconnecters.

3. Connect the analyzer hoses to the adapters. 4. Bleed the power steering system if _{the analyzer}

has never been used. Refer to Bleeding Power Steering System.

Ensure that the analyzer gate valve remains open during the bleeding procedure.

Important: Throughout the following testing procedure, the letters in _parentheses indicate specific pressures and flows.

Document the values of the pressures and the flows. Use the letters in _parentheses as references for comparing the values. 5. Run the engine at idle speed with the gate

valve open. Record the flow

(A)

and the pressure (B).

5.1. If the flow is below 2 gpm, then the pump may need repair. Continue the test.

5.2. If the pressure is above

200

psi, inspect the hoses for restrictions.

2-4

Power

Steering

System

Steering

6. Partially close the gate valve in order to build up to 700 psi. Record the flow (C).

7. Compare the values of flow (A) and flow (C).

If flow

(C)

drops more than 1 _{gpm under} flow (A) then:

8. Replace or rebuild the pump. 9. Refer to the appropriate procedure:

• Power Steering Pump Assemble

(P/S

Pump

Repair W/ Air Brakes) or

• Power Steering Pump Assemble (P/S Pump

Repair

W/

Hyd Brakes).

10. Replace the following components:

•

The

ring • The rotor • The vanes •

The

0-ring seals

11. Complete the following steps in _order to obtain the pressure value (D):

11.1. Close the gate valve for not more than five seconds, partially open the gate valve.

11.2. Close and partially open the valve two more times. Observe and record the pressure (D) each time that the gate is

closed.

12. Compare the pressures (D) to the specified pressures.

• If the recorded pressures are 100 psi lower

than specifications, than replace the pump flow control valve.

• If the pressures

(D)

are greater than the low

specifications and vary from each other by more than 100 psi

(1,450

BAR) than remove and clean the pump flow control valve.

• Inspect the pump flow control valve bore for

dirt _{or foreign materials,} clean the pump flow control valve bore.

• Inspect the system fluid for contamination. If

the fluid is contaminated, dissemble and clean the steering gear and the pump before assembly.

13. Increase the engine speed from idle to

approximately 1500 RPM. Record the flow (E). 14. Compare the values of flow (A

)

and flow (E).

Complete the folowing steps if flow (E) varies by more than 1 gpm from flow (A).

14.1. Remove and clean the pump flow control valve.

14.2. Inspect the pump flow control valve bore for dirt _{or foreign materials.} Clean the pump flow control bore.

14.3. Inspect the fluid for contamination. If _the fluid is _{contaminated, dissemble and}

clean the steering gear and the pump before assembly.

15.

Have

an assistant lightly turn the steering wheel into the left _{steering stop and} then the right steering stop.

Caution:

This

test

can

be

dangerous

If

not

performed

correctly. Keep

your

fingers

clear

of

steering

stops and

spacer

block

during

this

test.

Make sure

that the

spacer block

contacts

the

steering

stop squarely.

Contact

that

Is

_{not square could}

break

the steering

stop or dangerously

throw

or eject the

spacer

block.

Notice:

Do not hold the steering _wheel in the

full turn position longer than five seconds. To do so may damage the power steering pump. Important: Use a _{non-hardened 1.3 cm (0.5 in)}

steel spacer on the steering gear.

16. Use a _{long handle to hold the spacer} in place

in front of the steering stops, this action will prevent pressure relief poppets from tripping. 17. Record the pressure and the flow (F).

Verify that the following conditions exist:

•

The

pressures measured at the steering

stops are close in value to the maximum pump output (D).

•

The

flow drops below 1 _gpm.

If _{the above} conditions do not exist, the steering gear is leaking internally. _{Repair the}

steering gear.

18. Perform the following actions simultaneously.

•

Have

an assistant turn the steering wheel

slightly in _{both directions and then quickly} release the wheel.

• Observe the pressure gage.

Under normal conditions, the needle will move from the normal back pressure reading and snap back when the wheel is _released. A _{slow or sticking needle indicates} a sticking rotary valve in _{the steering gear.}

19. Complete the following steps if the pressure gage needle moves slowly or sticks:

19.1. Remove the rotary valve.

19.2. Disassemble and clean the rotary valve 20. If contamination exists in _{the system} oil,

dissemble and clean _{or replace the pump.} 21. Refer to the appropriate procedure:

21.1. Power Steering Pump Assemble

(P/S

Pump Repair

W/

Air Brakes) or 21.2. Power Steering Pump Assemble (P/S

Pump Repair

W/

Hyd Brakes).

Steering

Power

Steering System

2-5

Objectionable Hiss

Problem Action

There is a noisy relief valve in the hydraulic pump.

Noise is evident in all power steering systems.

Hissing is a _{common noise.} The hissing noise is most evident at standstill

parking. A hiss is a high _{frequency noise.}

The noise is _present in every valve and results from a high velocity fluid

passing over the valve orifice _edges.

There is not a relationship between the hissing noise and the performance of

the steering. A hiss may be expected when the steering wheel is at the end

of travel or when it is slowly turning at a standstill.

Do not replace the valve unless the hiss is _{extremely objectionable.} A

replacement valve will also exhibit _{some slight noise and} is _{not always} a _cure

for the objection.

____

Rattle or

Chuckle Noise

in

_{Steering Gear}

Problem

The steering _{gear mounting} is _loose.

The steering linkage is _loose.

The pressure hose is _{touching other}

parts of the vehicle.

The Pitman arm is _loose.

The over-center adjustment is

improper.

A slight rattle may occur on turns because of an increased clearance off the High Point. This is a normal

condition. Do not reduce the

clearance below the specified limit in

an attempt to eliminate this slight

rattle.

Action

1. Inspect the mounting hardware on the steering gear.

2. Torque the hardware to specifications.

1. Inspect the linkage pivot points for wear.

2. Replace any worn component.

Adjust the hose position. Do not bend the tubing by hand. Torque the pitman _{arm nut.}

Adjust to specifications.

Excessive

Wheel Kickback or

Loose Steering

Problem

Air is present in _{the system.}

The steering gear mounting is _loose.

The steering linkage joints are worn.

The steering gear mounting is improper.

Worn or maladjusted front wheel

bearings

Worn or damaged steering _gear

Action

1. Add power steering fluid to the power steering reservoir.

2. Bleed the system.

3. Inspect the hose connectors for proper torque and leakage.

Tighten the attaching bolts to the specified torque. Refer to Fastener Tightening Specifications.

Replace any loose parts.

Tighten the steering gear mounting bolt nuts to specifications. Refer to Fastener Tightening Specifications.

Adjust or replace the bearings Replace the steering gear.

2-6

Increase

in

Effort

While

Turning Steering

Wheel

The power steering fluid is low.

There leakag power

Power

Steering

System

Steering

Problem

is a _{high degree of internal} e _(power steering _pump or

steering gear).

Action Add an adequate amount of _{power steering} fluid.

Refer to Power Steering System Test Procedure.

Poor Return

of

Steering

Wheel

Problem

Under-inflated tires

The steering wheel is _{rubbing against}

the steering column cover.

The steering shaft bearings are tight

or frozen.

There is a binding in the steering linkage.

Misalignment of the steering gear to

the column.

["he _{suspension joints and the}

steering linkage are not adequately

lubricated.

Sticking or plugging in the steering

gear valve spool.

mproper front wheel alignment.

A kink in the supply hose.

Action

Inflate the tires to the specified pressure. Adjust the steering column cover.

Replace the bearings.

Replace any of the affected parts.

Align the steering column.

Lubricate the suspension joints and the steering linkage. Refer to Fluid _and

Lubricant Recommendations in _{Maintenance and Lubrication.}

Replace the steering gear. Refer to Power Steering Gear Replacement.

1. Inspect the front wheel alignment.

2. Adjust the front wheel alignment to specifications. Replace the hose.

Steering Wheel

Surges/Jerks While Turning

Problem

The power steering fluid is _low.

The pump pressure is insufficient.

The gear pressure relief valve is faulty.

The steering linkage is binding.

Steering Effort Hard

in

Both Directions

Problem

The tire pressure is _low.

A lack of lubrication in _{the suspension}

or ball joint (worn/contaminated

ioints).

There is a binding in the steering

linkage.

There is a misalignment of the

steering _{gear to} the column.

The power steering fluid is _low.

Action

Add an adequate amount of power steering fluid.

Refer to Power Steering System Test Procedure.

Replace the faulty gear pressure relief valve.

1. Inspect the steering linkage for any worn components.

2. Replace the worn components.

Action

Inflate the tires to the specified pressure. Refer to Tire Inflation Description in _Tires

and Wheels.

Lubricate and relubricate at the proper intervals or replace the joints. Refer to Fluid

and Lubricant Recommendations in _Maintenance and Lubrication. Replace any affected parts.

Align the steering column.

1. Add an adequate amount of power steering fluid. 2. nspect the lines and the joints _{for any external leakage.}

Steering

Power

Steering

System

2-7

Steering Effort

Hard

in

_{Both Directions}

(cont'd)

Problem

High internal leakage exists in the

steering _{gear or} in _{the pump.}

Misalignment of the front wheels.

Action Refer to Power Steering System Test Procedure.

Check and adjust the front wheel alignment to specifications.

Vehicle Leads

to

One

Side or

the Other

Problem

The road or wind conditions are poor.

The front wheels are misaligned.

An unbalanced steering gear valve.

If _{the steering gear valve} is

unbalanced, the steering effort will be

very light in the direction of the lead and heavy in _{the opposite direction.}

The steering shaft is _{rubbing the I.D.} of the shaft tube.

Action

1. Test drive the vehicle on a flat road. 2. Turn the vehicle in both directions. Adjust the front wheels to specifications.

Replace the steering gear. Refer to Power Steering Gear Replacement.

Align _{or replace the steering column.}

Foaming, Milky-Appearing

PS

Fluid,

Low

in

_Level

Problem Action

Air in the fluid and a _{loss of fluid due to internal pump}

leakage causing overflow.

1. Locate and repair the leak.

2. Bleed the power steering system. Refer to Bleeding Power Steering System.

Extremely cold temperatures will cause system aeration

if _{the power steering fluid is low.}

Hose or air leakage in _{the reservoir line.}

1. Locate and repair the leak

2. Bleed the power steering system. Refer to Bleeding Power Steering System.

Extremely cold temperatures will _{cause system aeration} if _{the power steering fluid is low.}

___

Low

Oil

_Pressure

_Due

_to

_{Restriction in}

_{the Hose}

Problem

The hoses are kinked.

A foreign object is stuck in _{the hoses.}

1.

2.

1.

2.

Action

Remove the kinks.

Replace the hoses as necessary. Remove the foreign object.

Replace the hoses as necessary.

Low

Oil

_Pressure

_Due

to

Steering

Gear

Problem

There is a loss of _{pressure due to} a

worn piston ring or a _scored

housing _bore.

There is leakage in _{the steering gear.} A damaged end limiter

Replace the steering

Replace the steering

Replace the end limiters. Refer to End Limiters Replacement. gear. Refer

gear. Refer

Action

to Power Steering Gear Replacement. to Power Steering Gear Replacement.