oil level ISUZU TROOPER 1995 Workshop Manual

GENERAL INFORMATION OA-1
GENERAL INFORMATION
CONTENTS
General Information ........................................................ /.. . . . . . . . . Section OA / Maintenance and Lubrication ............................................. ~·. . . . . . . . . . . . . Section 08
SECTION OA
GENERAL INFORMATION
CONTENTS
General repair instructions ...................... OA-1 Standard bolts torque
specifications .......... OA-9
How to use this manual. ......................... OA-2 Abbreviations
charts ............................. OA-10
Identification
....................................... OA-5 Service
parts identification plate ............... OA-12
Lifting instructions ................................ OA-7
GENERAL REPAIR INSTRUCTIONS
1. If a floor jack is used, the following precautions
are recommended.
Park
vehicle on level ground, "block" front or
rear wheels, set jack against the recommended
lifting points (see "Lifting instructions" in this
section), raise
vehicle and support with chassis
stands and then perform service operations.
2. Before performing service operations, disconnect
ground
cable from the battery to reduce the
chance
of cable damage and burning due to
short circuiting.
3. Use a cover on body, seats and floor to protect
them against damage and contamination.
4. Brake fluid and anti-freeze solution must be
handled with reasonable care, as they can cause
paint damage.
5. The use of proper tools and recommended
essential and available tools, where specified, is
important for efficient and reliable performance
of service repairs.
6. Use genuine lsuzu parts.
7. Used cotter pins, plastic clips, gaskets, 0-rings,
oil seals, lock washers and self-locking nuts
should be discarded and new ones should be
installed, as normal function of the parts cannot
be maintained
if these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in
groups. Keeping fixing
bolts and nuts separate
is
very important, as they vary in hardness and
design depending on position
of installation.
9. Clean the parts before inspection or reassembly.
Also clean oil
ports, etc. using compressed air,
and make certain
they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts
with oil or grease before installation.
11. When necessary, use a sealer on gaskets to pre­
vent leakage.
12. Carefully observe all specifications for bolt and
nut torques.
13. When removing or replacing parts that require
refrigerant
to be discharged from the air
conditioning system, be sure
to use the Vehicle
Refrigerant Recovery and Recycling Equipment
(VRRRE) to recover and recycle Refrigerant-
134a.
14. When a service operation is completed, make a
final check to be sure the service has been done
properly and the problem has been corrected.

(
(
(
MILEAGE/MONTHS
rn
I ffi
IN THOUSANDS
OF
MILES
(USE
ODOMETER READING)
(x 1000
miles)
~ +~
7.5 15 22.5
30
37.5 45 52.5
60
67.5
75
82.5
90
97.5
105
112.5
120 DESCRIPTION
1
CHECK
BATTERY
FLUID
LEVEL
12
2'-'.:j:
:':
';;;;;
I '' ''
,,,,,,,,,:
[}
2
CHECK
ENGINE
COOLANT
LEVEL
12
':iti:·:
(''''/''?
'';?
,,,,,,,;.;.,.,....
,,,~~
3
CHECK
BRAKE
AND
CLUTCH
FLUID
LEVEL
12
:;:;:;:;:·:·:·.
\::':\' '\"':(\':'''''''''
:'·'·'·:·.,.,,,,
d~~~~~~-------------~
)''
'"''''{''''
'}';;o;o;;
l':':':·:o·.·o·····
4
CHECK
FLUID
LEAKS
12
•.•••..••• ,,......
,,,,,,,,,,,
5
* CHANGE
ENGINE
OIL
12
:.•••:•····
f ) : •
: ; ' {
1:':''''
6
*REPLACE
ENGINE
OIL
FILTER
12
{\::::::::;
[:(o:'.
7
CHECK
COOLING
AND
HEATER
HOSES
12
I : ' :
?
,,,.,,,,,.,:,
.. ;
! • !
•••••••••.
8
CHECK
EXHAUST
SYSTEM
12
I
~
J
:
: ••;·,·····,:·:';';·
•••::::::::::·:;.;
I ;J
., ..... .
9
CHECK
FUEL
LINE
AND
FUEL
TANK/CAP
12
10
CHECK
ENGINE
DRIVE
BELTS
24
. .
I
I
11
CHECKTIRESANDWHEELS
12
li
1:;:~:
}::,
..... ::::, .. ,::,:,:,:,·····
j
12
CHECK
STEERING
OPERATION
12
1
r ., .. ,,.,,.
·
I
13
CHECK
BRAKE
LINES
AND
HOSE
12
~
~
<
.,>
/ ':'??i'
}
J
t
''}{
14
CHECK
DISC
BRAKES
12
10
}}
UL
'I I
•....
15
CHECK
BRAKE
PEDAL
PLAY
12
I"
.. )t
16
CHECK
PARKING
BRAKE
12
li
I
17
LUBE
ACCELERATOR
LINKAGE
6
,,.:
....
I
18
CHECK
SUSPENSION
AND
STEERING
12
••·•••·•··•
19
LUBE
BODY
AND
CHASSIS
6
1''''':'''''''''''
20
LUBE
FRONT
AND
REAR
PROPELLER
SHAFT 6
{:
!: • :•••••l
21
CHECK
PROPELLER
SHAFT FLANGE
TORQUE
12
•
22
*CHECK AUTOMATIC TRANSMISSION
FLUID
12
... ,, ,....
@{I{
,,,,,,,,
ttJ
·~+---------------!
23
CHECK
AUTO
CRUISE
CONTROL
LINKAGE
AND
HOSES
12
~ .
:l
!•••:
24
CHECK
CLUTCH
LINES
AND
HOSE
12
25
LUBE
CLUTCH
PEDAL
SPRING,
BUSHING
AND
CLEVIS
PIN
6
l':":"·:"ii
26
CHECK
CLUTCH
PEDAL
FREE
PLAY
12
1/JJ(
21
cHEcK sTARTER SAFETY swiTCH 12
1/,,,,.,,,,,,,,,
,,,,,,,,,
-~~~--~~~~~~-~~~~~[============J
28
CHECK
ACCELERATOR
LINKAGE
12
m ::::::::]
!•'····
'.!
Under
severe driving conditions,
additional
maintenance
is required.
Refer to
"Severe
driving
conditions".
SHADED AREA
INDICATES
SERVICE
TO
BE PERFORMED.
s: ~ 2 -1 m 2 )> 2 n m )> 2 c r­c m ::u n ~ 0 2 Q ~

FLUID LEVEL CHECK
A fluid loss in any system (except windshield
washer) may indicate a problem. Repair the system
at once.
Engine
oil level -Check level and add if
necessary. The best time to check the engine oil
level is
when the oil is warm. After stopping the
engine with the vehicle on a level surface, wait a
few minutes for the oil to drain back to the oil pan.
Pull
out the oil level indicator (dipstick). Wipe it
clean and push the oil level indicator back down all
the
way. Pull out the oil level indicator, keeping the
tip down, and look at the oil level on it.
Add oil, if needed, to keep the oil level above
the
"ADD" mark and between the "ADD" and
"FULL" marks in the operating range area. Avoid
overfilling the engine since this may cause engine
damage. Push
the oil level indicator back down all
the
way after taking the reading.
If you check the oil level when the oil is cold, do
not run the engine first. The cold oil will not drain
back
to the pan fast enough to give a true oil level.
Engine coolant level and condition -Check
engine coolant level in the coolant reservoir and
add engine
coolant if necessary. Inspect the engine
coolant and replace it if dirty or rusty.
Windshield washer fluid level -Check washer
fluid level in reservoir and add if necessary.
Power steering system reservoir level-Check
and keep at
proper level.
Brake master cylinder reservoir level -Check
fluid. Keep fluid at proper level. A low fluid level
can indicate
worn disc brake pads which may need
to be serviced.
Hydraulic clutch system -Check fluid l~vel in
the reservoir.
Add fluid as required.
Battery fluid level -Check fluid level in the
battery.
FLUID LEAK CHECK
Check for fuel, water, oil or other fluid leaks by
looking at the surface beneath the vehicle after it
has been parked for a while. Water dripping from
the air conditioning system after use is normal. If
you notice gasoline fumes or fluid at any time,
locate the source and correct it at once.
ENGINE OIL AND OIL FILTER
REPLACEMENT
Always use API SE, SF, SG, SH or ILSAC GF-1
quality oils of the proper viscosity.
When choosing an oil, consider the range of
temperatures the car will be operated in before the
next oil change. Then, select the recommended oil
viscosity
from the chart (Fig. OB-1).
Always change the oil and the oil filter as soon as
possible after driving in a dust storm.
MAINTENANCE AND LUBRICATION OB-5
ENGINE COOLING SYSTEM INSPECTION
Inspect coolant/anti-freeze. If coolant is dirty or
rusty, drain, flush and refill with new coolant. Keep
coolant at the proper mixture for proper freeze
protection,
corrosion inhibitor level and best engine
operating temperature.
Inspect hoses and replace if
cracked, swollen or deteriorated. Tighten hose
clamps if equipped with screw-type clamps. Clean
outside of radiator and air conditioning condenser.
Wash
filler cap and neck. To help ensure proper
operation, a pressure test of both the cooling
system and cap is also recommended.
EXHAUST SYSTEM INSPECTION
Visually inspect the exhaust pipes, muffler, heat
shields and hangers
for cracks, deterioration, or
damage.
Be alert to any changes in the sound of the exhaust
system
or any smell of fumes. These are signs the
system may be leaking or overheating. Repair the
system at once,
if these conditions exist. (See also
"Engine Exhaust Gas Safety" and "Three Way
Catalytic Converter" in Owner's manual.)
FUEL CAP, FUEL LINES, AND FUEL TANK
INSPECTION
Inspect the fuel tank, the fuel cap and the fuel lines
every
60,000 miles (96,000 km) for damage which
could cause leakage.
Inspect the fuel cap and the gasket for correct sealing
and physical damage. Replace any damaged parts.
DRIVE BELT INSPECTION
Check the belts driving the steering oil pump, the air
conditioning compressor, and the generator
for
cracks, fraying, wear, and correct tension every 30,000
miles (48,000 km). Adjust or replace as necessary.
WHEEL ALIGNMENT, BALANCE AND
TIRES OPERATION
Uneven or abnormal tire wear, or a pull right or left
on a straight and level road may show the need for
a wheel alignment. A vibration of the steering
wheel or seat at normal highway speeds means a
wheel balancing is needed. Check tire pressure
when the tires are "cold" (include the spare).
Maintain pressure as shown in the tire placard,
which is located on the driver's door lock pillar.
STEERING SYSTEM OPERATION
Be alert for any changes in steering action. An
inspection
or service is needed when the steering
wheel is harder
to turn or has too much free play, or
if there are unusual sounds when turning or parking.

MAINTENANCE AND LUBRICATION OB-13
APPROXIMATE CAPACITIES
Items Metric Measure U.S. Measure
Fuel tank 85L 22.5 Gal.
*Crankcase
Oil Change with Filter .............................. 5.4L 5.7 at
Oil Change without Filter ••••••••••••••••••\
0 •••• 0 ••• 4.7L
5.0 at
Coolant ........................................ MIT 8.8L 9.3 at
A/T 8.5L 9.0 at
Transmission
Manual
.......................................... 2.95L 3.1 at
Automatic ••••••••••••••••••\
•• 0 •••• 0 0 0 ••••••••••• 8.6L 9.1 at
Transfer
1.45L 1.5 at
Axle
Rear o o o 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 I 0 0 0 o o o o o o o 0 0 0 0 0 0 0 0 0 0 0 o o 1.8L 1.9 at
Front ........................................ ~ ... 1.5L 1.6 at
Power steering ••• 0 ••••••••• 0 ••••••••••••••••••\
0 •••• 1.0L 1.1 at
Air conditioning (R-134a) o o 0
0 0 0 0 0 0 0 0 I 0 0 0 0 0 o o 0 o 0 0 0 0 0 0 0 0.75kg 1.651b
* Crankcase capacities shown are approximate refill capacities.
After
refill, recheck oil level.

COMPRESSOR OVERHAUL 10-3
GENERAL INFORMATION
COMPRESSOR OIL
OIL SPECIFICATION
• The HFC-134a system requires a synthetic
(PAG) compressor oil whereas the R-12 system
requires a
mineral compressor oil. The two oils
must never be mixed.
• Compressor (PAG) oil varies according to com­
pressor model. Be sure to use oil specified for
the model of compressor.
• Always use HFC-134a Vane Rotary Type Com­
pressor Oil
(AIPDN Part No. 2-90188-301-0)
HANDLING OF OIL
• The oil should be free from moisture, dust,
metal powder, etc.
• Do not mix with other oil.
•
The water content in the oil increases when
exposed to the air. After use, seal oil from air
immediately.
(HFC-134a Vane Rotary Compressor Oil absorbs
moisture very easily.)
•
The compressor oil must be stored in steel
containers, not in plastic containers.
COMPRESSOR OIL CHECK
The oil used to lubricate the compressor is circul­
ating with the refrigerant.
Whenever replacing any component of the system
or a large amount of gas leakage occurs, add oil to
maintain the original amount of oil.
Oil Capacity.
Capacity
total in system 150cc (5.0 fl.oz.)
Compressor (Service
parts)
charging amount 15 0cc (5
·0
fl.oz.)
Checking and Adjusting for Used Compressor
1. Perform Oil return operation.
(Refer to "Oil Return Operation" in this section.)
2. Discharge and recover refrigerant and remove
the compressor.
3. Drain the compressor oil and measure the
extracted oil with a measuring cylinder (Fig. 1 D-
2).
Fig. 1D-2
4. If the amount of oil drained is much less than
90cc (3.0 fl.oz.), some refrigerant may have
leaked out. Conduct leak tests on connections of
each system, and if necessary, repair or replace
faulty parts.
5. Check the compressor oil for contamination.
(Refer to "Contamination of Compressor Oil" in
this section.)
6. Adjust oil level following the procedure below
(Fig. 1 D-3).
Collected Amount
more than 90cc
(3.0 fl.oz.)
Charging Amount
same as collected amount
less than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
7. Install the compressor, then evacuate, charge
and
perform oil return operation.
8. Check system operation.
When it is impossible to perform oil return oper­
ation, the compressor oil should be checked in the
following order:
1. Discharge and recover refrigerant and remove
the compressor.
2. Drain the compressor oil and measure the
extracted oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 90cc (3.0 fl.oz.) of oil is extracted
from the compressor, supply same amount of
oil to the compressor to be installed.
If
the amount of oil extracted is less than 90cc
(3.0 fl.oz.),
recheck the compressor oil in the
following order:
5. Supply 90cc (3.0 fl.oz.) of oil to the compressor
and install it onto the vehicle.

1 D-4 COMPRESSOR OVERHAUL
6. Perform oil return operation.
7. Remove the compressor and recheck the
amount of oil.
8. Adjust the compressor oil, if necessary.
Collected Amount
more than 90cc
(3.0
fl.oz.)
Charging Amount
same as collected amount
less than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
Checking and Adjusting for Compressor
Replacement
150cc (5.0 fl.oz.) of oil is charged in compressor
(service parts).
So it is necessary to drain the
proper
amount of oil from the new compressor.
1. Perform oil return operation.
2. Discharge and recover refrigerant and remove
the compressor.
3. Drain the compressor oil and measure the
extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust oil level as required.
Amount of oil drained
from used compressor
less than 90cc
(3.0
fl.oz.)
Draining amount of oil
from new compressor
Same as drained
amount
more than 90cc (3.0 fl.oz.) 90cc (3.0 fl.oz.)
6. Evacuate, charge and perform oil return oper­
ation.
7. Check system operation.
CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor
oil. Even if the compressor runs for a
long period
of time (approximately 1 season), the
oil never becomes contaminated as long
as there is
nothing
wrong with the compressor or its method
of use.
Inspect the extracted oil for any of the following
conditions:
• The capacity of the oil has increased.
• The oil has changed color to red.
• Foreign substances, metal powder, etc., are
present in the oil.
If any of these conditions exists, compressor oil
is contaminated. Whenever contaminated com­
pressor
oil is discovered, the receiver/dryer must
be
replaced.
OIL RETURN OPERATION
There is close affinity between the oil and the
refrigerant. During normal operation, part
of the oil
recirculates
with the refrigerant in the system.
When checking the
amount of oil in the system, or
replacing any component of the system, the com­
pressor
must be run in advance for oil return oper­
ation. The procedure is as
follows:
1. Open the all doors and engine hood.
2. Start the engine and air conditioning switch is
"ON" and Set the fan control knob at its hig­
hest position.
3. Run the compressor for more than 20 minutes
between
800 and 1,000 rpm in order to operate
the system.
4. Stop the engine.
REPLACEMENT OF COMPONENT PARTS
When replacing system component parts, supply
the following
amount of oil to the component parts
to be installed.
Component parts to be installed Amount of oil
Evaporator 50cc
(1.7
fl.oz.)
Condenser 30cc
(1.0 fl.oz.)
Receiver/dryer 30cc
(1.0 fl.oz.)
Refrigerant line (one piece) 1 Occ (0.3 fl. oz.)
Fig. 1 D-3
•

POWER STEERING GEAR AND PUMP 381 -1
SECTION 381
POWER STEERING GEAR AND PUMP
w CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Fasteners
that are not reused, and those requiring thread locking compound, will be called out. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
CONTENTS
General Description ............................ 3B1- 1
Steering Wheel Free Play Adjustment .... 3B1-5
Power Steering
Gear........................ 3B1-1
Steering Gear ................................ 3B1-6
Hydraulic Pump .............................. 3B1- 1
Power Steering Pump ...................... 3B1-8
Pressure Switch
............................. 3B1-1
Unit Repair ...................................... 3B1- 9
Power Steering System Test
................. 3B1-3
Steering Gear ................................ 3B1-9
On-Vehicle Service ............................. 3B1- 4
Power Steering Pump ...................... 3B1-14
Maintenance
................................. 3B1- 4
Main Data and Specifications ................ 3B1-17
Fluid Level .................................... 3B1- 4 General Specifications ...................... 3B1-17
Bleeding The Power Steering System .... 3B1-4
Torque Specifications ....................... 3B1-17
Bleeding Procedure ......................... 3B1-4 Special Tools.................................... 3B1-18
Flushing The Power Steering System .... 3B1-4
GENERAL DESCRIPTION
The hydraulic power steering system consists of a
pump, an oil reservoir, a steering gear, a pressure
hose and a return hose.
POWER STEERING GEAR
The power steering gear has a recirculating ball
system which acts as a rolling thread between the
worm shaft and the rack piston. When the worm shaft
is
turned right, the rack piston moves up in gear.
Turning the worm shaft left moves the rack piston
down in gear. The rack piston teeth mesh with the
sector, which is part ofthe sector shaft.
Turning the worm shaft turns the sector shaft, which
turns the wheels through the steering linkage.
The control valve in the steering gear directs the
power steering fluid to either side of the rack piston.
The rack
piston converts the hydraulic pressure into
a mechanical force. If the steering system becomes
damaged and loses hydraulic pressure, the vehicle
can be controlled manually (Fig. 381-1).
HYDRAULIC PUMP
The hydraulic pump is vane-type design. The
submerged pump has housing and internal parts that
are inside the reservoir and operate submerged in oil.
There are two bore openings at the rear of the pump
housing. The larger opening contains the cam ring,
pressure
plate, thrust plate, rotor and vane assembly,
and end plate. The smaller opening contains the
pressure
line union, flow control valve and spring
(Fig. 381-2).
PRESSURE SWITCH
When hydraulic pressure reaches 3920 ± 690 kPa
(570 ± 100 psi), the pressure switch closes causing
Engine
Control Module (ECM) to actuate the idle air
control valve to prevent the overload-induced engine
speed down. The switch opens
when hydraulic
pressure drops to 2970 ± 560 kPa (430 ± 80 psi).

POWER STEERING SYSTEM TEST
TEST PROCEDURE
Test of fluid pressure in the power steering system is
performed to determine whether
or not the oil pump
and
power steering unit are functioning normally.
The power steering system test is method used to
identify and
isolate hydraulic circuit difficulties. Prior
to performing this test, the following inspections and
corrections,
if necessary, must be made.
[!) INSPECT
• Pump reservoir for proper fluid level.
•
Pump belt for proper tension.
• Pump driver pulley condition.
1. Place a container under the pump to catch the
fluid when disconnecting or connecting the
hoses.
2. With the engine NOT running, disconnect the
pressure hose
at the power steering pump and
install Power Steering tester (Fig. 3B1-3).
The gage
must be between the shutoff valve and
pump.
Open the shutoff valve.
li5\l Tester: J-29877-A
~ Adapter: J-39213
3. Check the fluid level. Fill the reservoir with power
steering fluid, to the "Full" mark. Start the engine
and,
momentarily holding steering wheel against
stop, check the connections at tester
for leakage.
4. Bleed the system. Refer to "Bleeding the Power
Steering
System".
POWER STEERING GEAR AND PUMP 381-3
5. Start the engine and check the pump fluid level.
And power steering fluid if required. When the
engine is at
normal operating temperature,
increase engine speed to 1500 rpm.
U7 CAUTION:
VI Do not leave shutoff valve fully closed for more
than 5 seconds,
as the pump could become
damaged
internally.
6. Fully close the shutoff valve. Record the highest
pressures.
• If the pressure recorded is within 9300-9800
kPa (1350-1420 psi), the pump is functioning
within its specifications.
• If the pressure recorded is higher than 9800 kPa
(1420 psi), the valve in the pump is defective.
• If the pressure recorded is lower than 9300 kPa
(1350 psi), the valve or the rotating group in the
pump is defective.
7. If the pump checks within specifications, leave the
valve open and turn (or have someone else turn)
the steering
wheel fully in both directions. Record
the highest pressures and compare
with the
maximum pump pressure recorded in step
6. If
this pressure cannot be built in either (or one) side
ofthe gear, the gear is leaking internally and must
be disassembled and repaired.
8. Shut the engine off, remove the testing gage,
reconnect the pressure hose, check the
fluid level
and make the needed repairs.
9. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Shut off Valve
J-29877-A
Oil Pressure Gauge
J-29877-A
Fig. 3B1-3

381 - 4 POWER STEERING GEAR AND PUMP
ON-VEHICLE SERVICE
MAINTENANCE
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regular
intervals
and fluid added when required. Refer to
"MAINTENANCE AND LUBRICATION" in section OB
ofthe manual for type offluid to be used and intervals
for filling.
If the system contains some dirt, flush it as detailed
later
in this section. If it is exceptionally dirty, both the
pump and the gear must be completely disassembled
before further usage.
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight.
Make sure the clips, clamps and supporting tubes and
hoses are in
place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected
or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to "Bleeding
the Power Steering System" in this section.
FLUID LEVEL
1. Run the engine until the power steering fluid
reaches normal operating temperature, about
55°C (130°F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid
as specified in "MAINTENANCE AND LUBRI­
CATION" in Section OB to the proper level and
install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced,
air must be bled from
the system. Refer to "Bleeding the Power
Steering
System" in this section.
BLEEDING THE POWER STEERING
SYSTEM
When a power steering pump or gear has been
installed, or an oil line has been disconnected, the air
that has entered the system must be bled out before
the vehicle is operated. If air is allowed to remain in
the power steering fluid system, noisy and
unsatisfactory operation of the system may result.
BLEEDING PROCEDURE
When bleeding the system, and any time fluid is
added
to the power steering system, be sure to use
only power steering fluid as specified in
"MAINTENANCE AND LUBRICATION" in section OB.
1. Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds.
Do
not turn the steering wheel. Then turn the
engine off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise the front end of the vehicle so that the
wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel
right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle and turn the steering wheel
slowly from lock to lock.
9. Stop the engine. Check the fluid level and refill
as required.
10.
If the fluid is extremely foamy, allow the vehicle
to stand a few minutes and repeat the above
procedure.
~ INSPECT
• Belt for tightness.
• Pulley for looseness or damage. The pulley
should not wobble with the engine running.
• Hoses so they are not touching any other parts
of the vehicle.
• Fluid level
and fill to the proper level.
FLUSHING THE POWER STEERING
SYSTEM
1. Raise the front end of the vehicle off the ground
until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the
pump.
Position the line toward a large container to
catch the draining fluid.
3. While running the engine at idle, fill the reservoir
with new power steering fluid. Turn the steering
wheel in both directions. DO NOT contact wheel
stops or hold the wheel in a corner, or fluid will
stop and the pump will be in pressure relief mode.
A sudden
overflow from the reservoir may
develop if the wheel is held at a stop.
4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system
as described in "Bleeding The Power Steering
System". Operate the engine for about 15
minutes.
Remove the
pump return line at the pump inlet
and plug the connection on the pump. While
refilling the reservoir, check the draining fluid for
contamination. If foreign material is still evident,
replace all lines, disassemble and clean or replace
the power steering system components. Do not
re-use any drained power steering fluid.
~
~

48 -28 REAR AXLE
l•!-.1 DISASSEMBLY
Using special tool, grip it with a vice, and set the
differential (Fig. 48-68).
I ®.1 Side gear holder: J-41 033
Fig. 48-68
1.
Screw
• Gradually and evenly loosen the 4 fixing
screws of the differential cages A and 8 (Fig.
48-69).
Fig. 48-69
2. Differential cage A
3. Thrust washer
4. Spring disc
• When removing the spring disc, friction disc,
and
friction plate, place them in order for
clear distinction of left and right use.
5. Spring disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure ring
11. Side gear
12. Pinion and pinion shaft
13. Side gear
14. Pressure
ring
15. Friction disc
16. Friction plate
17. Friction disc
18.
Friction plate
19. Spring disc
20. Spring disc
21.
Thrust washer
22. Differential cage B
IL•IINSPECTION AND REPAIR
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition is found through inspection.
Visual check
Check
the following parts for wear, damage, noise or
any other abnormal conditions.
• Friction disc, friction plate and spring disc
CD Sliding surfaces
® Projections
Fig. 48-70
• Pressure ring
@ Sliding surface with the friction disc
When nicks or scratches are found, polish
with an oil stone and repair on a level block
using a
compound.
@ Sliding spherical surface with the pinion
gear
® Sliding surface with the side gear
® V-shaped groove of the pressure ring and V­
shaped section
of the pinion shaft
(j) Fitting section with the case
® Face contacting the inner surface of the
differential case
Repair
burrs and nicks using an oil stone.