oil ISUZU TF SERIES 2004 Workshop Manual

POWER-ASSISTED STEERING SYSTEM 3B-27

Power Steering Pump Disassembled View

RTW43BMF000301
Legend
(1) Bolt
(2) Suction Pipe
(3) O-ring
(4) Shaft Assembly
(5) Oil Seal
(6) Front Housing
(7) O-ring
(8) O-ring
(9) Side Plate
(10) Rotor and Vane
(11) Pin
(12) Cam

(13) Pump Cartridge Assembly
(14) O-ring
(15) Snap Ring
(16) Rear Housing
(17) Bolt
(18) Spring
(19) Relief Valve
(20) O-ring
(21) Connector
(22) Bush
(23) Pressure Switch Assembly

Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent). Be
careful not to expose the oil seal of shaft assembl
y
to solvent.
2. Remove the bolt, suction pipe and O-ring.
Remove the O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the pressure switch assembly.
5. Remove the bolt, rear housing and O-ring.
6. Remove the snap ring.
7. Remove the shaft assembly.
8. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
9. Remove the pump cartridge assembly from the front
housing.
10. Remove two O-rings.

3B-28 POWER-ASSISTED STEERING SYSTEM

Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.

Rotor
442RS002
Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When par
t
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.

Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.

Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finge
r
nail.
The parts with minor scores may be reused after lapping
the face.

Relief Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).

Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.

O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.

Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. I
f
system fails to function properly, disconnect connecto
r
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.

Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.

POWER-ASSISTED STEERING SYSTEM 3B-29

3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install rotor and vanes to cam.
5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten i
t
to specified torque.
Torque: 22-26 N




m (2.2-2.7 kg




m/16-20 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten i
t
to specified torque.
Torque: 7.8-12 N




m (0.8-1.2 kg




m/6-9 lb ft)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 49-69 N




m (5.0-7.0 kg




m/36-51 lb ft)
14. Install pressure switch assembly and tighten it to
specified torque.
Torque: 15-20 N




m (1.5-2.0 kg




m/11-14 lb ft)

3B-30 POWER-ASSISTED STEERING SYSTEM

Main Data and Specifications
General Specifications
Oil pump Type Vane
Operating fluid
ATF DEXRON®
III



Torque Specifications
6VE1 N
m (kg
m/Ib ft)


RTW43BMF000401

POWER-ASSISTED STEERING SYSTEM 3B-33

Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait a
t
least 5 minutes. (with SRS air bag)
4. Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly. (with SRS air bag)
5. Disable the SRS (Refer to "Disabling the SRS" in
this section). (with SRS air bag)
6. Check the both side hole of the steering cover. (with
SRS air bag)
060R300025


7. Check the position of the pins in a hole. Push the
pin in the direction of an arrow. (with SRS air bag)
060R300032
8. Push the four pins at 
5
6 mm bar. (with SRS air
bag)
060R300031
9. Cancel the lock four pins. (with SRS air bag)

POWER-ASSISTED STEERING SYSTEM 3B-37

Steering Wheel
Steering Wheel and Associated Parts
430R300013
Legend
(1) Horn Lead
(2) SRS Connector
(3) Steering Wheel
(4) Steering Wheel Fixing Nut
(5) Inflator Module or Horn Pad



Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait a
t
least 5 minutes. (with SRS air bag)
4.
Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly. (with SRS air bag)
5. Disable the SRS (Refer to "Disabling the SRS" in
this section). (with SRS air bag)

3B-40 POWER-ASSISTED STEERING SYSTEM



430RX005-X
14. Remove steering column cover.
15. Disconnect the wiring harness connectors located
under the steering column then remove combination
switch and SRS coil assembly.

Installation
1. Align the setting marks made when removing then
install steering wheel.
Refer to the adjustment method in case a mark is
not attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601

CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
2. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 31 - 39 N





m (3.2 – 4.0 kg





m/23 - 29 lb ft)
3. Support the inflator module and carefully connect the
SRS connector and horn lead. (with SRS air bag)
060R300041
4. Connect the horn leads at center of wheel. (without
SRS air bag)
NOTE: Horn leads is letting a bracket top pass.
(Plastic type steering wheel only)



RTW43BSH000301

POWER-ASSISTED STEERING SYSTEM 3B-43

Combination Switch
Combination Switch and Associated Parts


This illustration is based on the RHD model.
RTW43BLF000601
Legend
(1) Steering Column Cover
(2) Steering Wheel
(3) Inflator Module or Horn Pad
(4) Combination Switch and SRS Coil Assembly
(5) Instrument Panel Lower Cover
(6) Driver Knee Bolster (reinforcement)


Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait a
t
least 5 minutes. (with SRS air bag)
4.
Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly. (with SRS air bag)
5. Remove the engine hood opening lever, then
remove instrument panel lower cover.
6. Remove the driver knee bolster (reinforcement).

3B-46 POWER-ASSISTED STEERING SYSTEM


CAUTION:
When turning the SRS coil
counterclockwise to full, stop turning if resistance
is felt. Forced further turning may damage the cable
in the SRS coil.
(with SRS air bag)
826RW014
Legend
(1) Neutral mark





430RX005-X
16. Remove steering column cover.
17. Disconnect the wiring harness connectors located
under the steering column then remove combination
switch and SRS coil assembly. (with SRS air bag)
NOTE: The SRS coil is a part of the combination switch
assembly, which can not be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly. (with SRS air bag)
430R300014

Installation
1. Install the combination switch assembly with SRS
coil. (with SRS air bag)
2. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark. (with SRS
air bag)


3. Connect the wiring harness connectors located at
the base of steering column.
4. Install the air conditioning lower duct.
5. Install the steering column cover.
CAUTION:
When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.
(with SRS air bag)
825RS048

POWER-ASSISTED STEERING SYSTEM 3B-49

Lock Cylinder
Lock Cylinder and Associated Parts

This illustration is based on the RHD model.
RTW43BLF000701
Legend
(1) Steering Column Cover
(2) Steering Wheel
(3) Inflator Module or Horn pad
(4) Combination Switch and SRS Coil Assembly
(5) Steering Column Assembly
(6) Lock Cylinder Assembly
(7) Instrument Panel Lower Cover
(8) Driver Knee Bolster (reinforcement)


Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait a
t
least 5 minutes. (with SRS air bag)
4. Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)