POWER STEERING 7 A PUMP

Transcription

1 POWER STEERING 7 A PUMP

2 Tle of Contents Pge Torque Speifitions A-1 Tools/Selnts/Fluids A-1 Preutions A-1 Cheking Power Steering Pump Fluid Level. 7A-1 With Cold Engine A-1 With Engine Wrm From Opertion.... 7A-2 Filling nd Air Bleeding Power Steering System A-2 Pump Drive Belt Tension Adjustment A-2 Pump Pulley Replement A-3 Removl A-3 instlltion A-3 Pge Power Steering Pump And Cooler A-4 Replment A-4 Instlltion A-7 Low Pressure Hose (Control Vlve-to-Cooler) A-8 Removl A-8 Instlltion A-8 Priority Vlve Kit (79691A1) Informtion.... 7A-10 Instlling Reservoir A-10 Instlling Priority Vlve A-11 Filling System with Fluid A-15 Mintenne A-15 System Flow Digrm A-16 7A-0 - POWER PUMP STEERING

3 Torque Speifitions Fstener Lotion L. Ft. L. In. N m Crnkshft Pulley to Hrmoni Blner Hrmoni Blner to Crnkshft Pump Mounting Brket to Engine Reirultion Pump Pulley Tools/Selnts/Fluids Desription Prt Numer Pulley Instller A1 Quiksilver Perfet Sel Dexron II (ATF) Otin Lolly Kent-Moore Speil Tools Pulley Removl Tool J Cn e ordered from: Kent-Moore Tools, In Little Mk Roseville, MI Phone: (313) Cn e ordered from: Kent-Moore Tools, In Little Mk Roseville, MI Phone: (313) ! CAUTION Do not pry on power steering pump or lterntor when djusting elt tension. Serious dmge my result. Cheking Power Steering Pump Fluid Level IMPORTANT: Use only Quiksilver Power Trim nd Steering Fluid, or utomti trnsmission fluid (ATF), Dexron II, in power steering system. WITH COLD ENGINE 1. Stop engine nd position drive unit so tht it is stright k. 2. Remove fill p/dipstik from poewr steering pump nd note fluid level. Preutions! CAUTION Do not operte engine without ooling wter eing supplied to wter pikup pump or wter pump impeller will e dmged nd susequent overheting dmge to engine my result Fill Cp -Power Steering Pump 3. Level should e etween FULL COLD mrk nd ottom of dipstik.! WARNING Alwys disonnet ttery les from ttery efore working on engine to prevent fire or explosion Proper Fluid Level With Engine Cold POWER STEERING - 7A-1

4 4. If fluid level is low ut still visle in pump reservoir, dd fluid thru fill p opening to ring level up to FULL COLD mrk on dipstik. Do not overfill. WITH ENGINE WARM FROM OPERATION 1. Stop engnie nd position drive unit so tht it is stright k. 2. Remove fill p/dipstik from power steering pump nd note fluid level. 3. Level should e etween the FULL HOT mrk nd ADD mrk on the dipstik Proper Fluid Level With Engine Wrm 4. If level is low (elow ADD mrk), ut still visile in pump reservoir, dd fluid thru fill p opening to ring level up to FULL HOT mrk on dipstik. Do not overfill. Filling nd Air Bleeding Power Steering System IMPORTANT: Powert steering system must e filled extly s explined, following, to e sure tht ll ir is led from the system. All sir msut e removed, or fluid in pump my fom during opertion nd e dishrged from pump reservoir. Fomy fluid my lso use poewr steering system to eome spongy resulting in poor ot ontrol. 1. Position drive unit so tht it is stright k. Remove p from power steering pump nd hek fluid level with dipstik tthed to fill p (provided) Add fluid s required, to ring level up to orreet level. IMPORTANT: Use only Quiksilver Power Trim nd Steering Fluid, or utomti trnsmission fluid (ATF), Dexron II, in power steering system. 2. Turn steering whell k-nd-forth to end of trvel i eh diretion severl times: then, rehek fluid level nd dd fluid, if neessry. 3. Instll vented fill p.! CAUTION DO NOT operte engine without wter eing supplied to sewter pump pikup or pump impeller my e dmged nd susequent overheting dmge to engine my result. 4. Strt engine nd run t fst ilde ( RPM) until engine rehes norml operting temperture. During this time, turn steering wheel knd-forth to end of trvel in eh diretion severl times. 5. Position drive unit so tht it is stright k nd stop engine. Remove fill p from pump. Allow ny fom in pump reservoir to disperse; then, hek fluid level nd fluid s required, to ring level up to FULL HOT mrk on dipstik. Do not overfill. Instll fill p seurely. IMPORTANT: Drive unit must e positioned stright k nd power steering fluid must e hot to urtely hek fluid level. 6. If fluid is still fomy (in Step 5), repet Steps 4 nd 5 until fluid does not fom nd level remins onstnt. Pump Drive Belt Tension Adjustment IMPORTANT: Refer to Preutions in this setion efore proeeding. IMPORTANT: DO NOT pry in pump ody. 1. Instll drive elt on pulleys nd djust tension s follows:. Pivot pump ttin tension. 7A-2 - POWER STEERING

5 . Tighten retining olts. 4. While holding tool with suitle wrenh, turn threded srew until pulley is removed Belt Defletion No More Thn 1/4 Inh (6 mm) Mximum 2. Chek elt tension using either of two methods, following nd redjust pump, if neessry, to otin proper elt tension.. Using strnd tension guge, tke guge reding t midpoint of power steering pump elt. Guge should red ls. ( N m).. Chek elt tension y pushing down on upper strnd of elt t elt midpoint. Belt should depress 1/4 in. (6 mm). Pump Pulley Replement - Kent-Moore Pulley Removl Tool (J-25034) INSTALLATION Instll pulley, s follows, using pulley instller tool ( A1), nd long stright edge: 5. Ple pulley on pump shft. 6. Thred stud ll the wy into pump shft. Ple ering over stud. Do not use sper from kit. 7. Thred nut onto shft. Thred tool shft (nd nut) ll the wy onto stud (threded into pump pulley). 8. Using long stright edge (to hek drive elt lignment), turn lrge pusher nut until drive elt is prllel to stright edge. REMOVAL IMPORTANT: Kent-Moore Tool J must e used to remove the pressed-on pulleys used on power steering pumps. This tool hs n end on it tht will not mushroom the end of the pump shft. DO NOT use Kent-Moore Tool J to remove these pulleys. This tool hs tpered end nd will dmge the shft. 3. Instll Kent-Moore Tool J on end of pulley nd shft s shown POWER STEERING - 7A-3

6 Power Steering Pump And Cooler Replment IMPORTANT: Refer to Preutions, in this setion BEFORE proeding. 1. Instll pulley. 3. Instll 40 inh (1016 mm) drive elt inh (1016 mm) Drive Belt 4. Instll 37 inh (940 mm) drive elt over irulting pump pulley Instll oltsnd torque to 20 l. ft. (27 N m) inh (940 mm) Drive Belt Bolts nd Lokwshers A-4 - POWER STEERING

7 5. Instll front mount ssemly with power steering pump ssemly. Tighten olts seurely. 7. Atth power steering pump re to pump /4 inh (70 mm) Bolts, Wshers nd Lokwshers. Tighten seurely. - Bolts, Wshers nd Lokwshers. Tighten seurely. 6. Atth power steering pump rket to engine. Torque olt to 30 l. ft. (41 N m). - 7/8 inh (22 mm) Long Bolt nd Wsher 8. Instll 37 inh (940 mm) drive elt over pump pulley /4 inh (32 mm) Long Bolt Without Closed Cooling. 1-1/2 inh (38 mm) Long Bolt With Closed Cooling inh (940 mm) Drive Belt 9. Adjust drive elt tension POWER STEERING - 7A-5

8 10. Route hydruli hoses s shown. 11. DDIS AND EST MODELS: Instll fluid ooler nd tighten hose lmp-srew seurely Clmp-Srew, Tighten Seurely 12. BREAKER POINTS IGNITION MODELS: Instll fluid ooler nd tighten srew seurely. DDIS Ignition - Hydruli Hose Routing inh (25 mm) Bolts - Power Steering Fluid Cooler Breker Points Ignition - Hydruli Hose Routing 7A-6 - POWER STEERING

9 13. Instll long wter hose nd tighten hose lmps seurely. INSTALLATION 1. Using hose lmp, instll new hose on k of pump. Tighten lmp seurely Hose Clmp - Hose 2. Using hose lmp, instll hose on fluid ooler. Tighten lmp seurely. - Hose Clmps 14. Instll wter hoses to power steering fluid ooler nd tighten lmps seurely Hose Clmps - Fluid Cooler - Hose Clmp - Hose POWER STEERING - 7A-7

10 3. Fill nd ir leed system. Refer to Setion 1B - Mintenne (see Tle of Contents ). 2. Remove lrge fitting from ontrol vlve t trnsom. Remove hose. Low Pressure Hose (Control Vlve-to-Cooler) REMOVAL NOTE: Cth fluid tht drins from hose, ooler nd pump in suitle ontiner. 1. Loosen hose lmp nd remove hose from fluid ooler Erlier Style Control Vlve - Lrge Fitting Lter Style Control Vlve - Fluid Cooler - Hose Clmp - Hose INSTALLATION! CAUTION Route hoses extly s shown elow. This will help void stress on the hose fittings nd will help void kinks in the hoses. IMPORTANT: Be reful to not ross-thred or over-tighten hose fittings. 7A-8 - POWER STEERING

11 3. Thred lrge fitting into ontrol vlve. Position hose properly (s prior to removl). Erlier Style Control Vlve: Torque lrge fitting to l. ft. (27-34 N m). 5. Using hose lmp, instll hose on fluid ooler. Tighten lmp seurely Lrge Fitting Lter Style Control Vlve: Torque fittings to 23 l. ft. (31 N m) Fluid Cooler - Hose Clmp - Hose 6. Fill nd ir leed system. Refer to Setion 1B - Mintenne (see Tle of Contents ) Route hose long flywheel housing nd seure with J-lmp(s) provided POWER STEERING - 7A-9

12 Priority Vlve Kit (79691A1) Informtion This kit informtion (in Instlltion Instrution form) is provided to ssist personnel when serviing dul instlltions where oth engines re equipped with power steering pumps, oolers, relted hrdwre nd hoses, nd one trnsom ssemly is equipped with power steering. Although the system my lredy e instlled, refer to pproprite setions nd follow instrutions tht relte to your tsk when serviing those omponents. 2. Position ottle reservoir in mounting rket nd seure with retiner spring. NOTE: A system flow digrm is loted on the lst pge of this setion. Instlling Reservoir 1. Mount reservoir rket.. Find lotion etween oth power steering pumps tht ffords oth essiility nd esy visul inspetion of fluid level. Lotion must e t lest 6 in. (152 mm) higher thn pump p to llow fluid from reservoir to flow freely to pumps (preferly on trnsom or on forwrd engine omprtment wll).. Instll reservoir mounting rket with hrdwre supplied. d - Reservoir Brket - Reservoir Spring Retiner T - Srew nd Wsher (Not Shown in This View) d - Reservoir Bottle e - Retiner Spring e IMPORTANT: A two-wy vlve is required on the reservoir p for old wether opertion elow 40 F (4 C). 3. If required, instll two-wy vlve in reservoir p y removing vent from over nd repling it with two-wy hek vlve. - Mesurement - 6 In. (152 mm) Minimum Reservoir Cp - Vent A-10 - POWER STEERING

13 Reservoir Cp - Two-Wy Vlve (Instlled) 4. Cut two hoses (from ulk hose supplied) of suffiient length to extend from ottom fittings on reservoir to fill ps on power steering pumps. Allow extr hose for routing. IMPORTANT: When routing nd instlling hoses in the following steps, e sure tht the end rdius in the hose is suffiient to eliminte lod eing pled on power steering pump fill p. 5. Connet hoses, tht were just ut, to reservoir nd power steering pump ps (from kit). Seure with hose lmps. Tighten seurely. 6. Seure hoses with St-Strps to keep them elow reservoir fluid level line nd wy from het nd moving prts. - Reservoir - Hoses from Pumps - Hose Clmps Instlling Priority Vlve NOTE: Priority vlve mounting rket n e used in vrious mounting onfigurtions. d e Power Steering Pump Cp (Port nd Strord) - Hose to Reservoir - Hose Clmp d - St-Strps e - Bend Rdius (Port nd Strord) 1. Instll priority vlve mounting rket Find entrl lotion tht will e essile for mking nd heking hose onnetions. Ensure tht lotion will llow 2 in. (51 mm) or more, ove nd elow priority vlve for hose onnetions nd routing (preferly on stringer ner trnsom) POWER STEERING - 7A-11

14 . Mount rket using lg olts nd wshers supplied. - Mounting Brket - Lg Bolts nd Wshers NOTE: The 90 elow lotions on priority vlve re mrked with T stmped into the vlve. 2. Apply liquid pipe joint seler to threds nd instll fittings into priority vlve. d - Bolt nd Wsher - Wsher nd Nut (Not Shown in This View) - Brket d - Priority Vlve NOTE: Engines with power steering re equipped with hose tht is onneted to the power steering fluid ooler. A fitting on the other end of the hose would normlly e onneted to the power steering ontrol vlve. These hoses re not used nd re repled with ulk hose supplied with priority vlve kit. 4. Remove nd disrd old (ontrol vlve-to-ooler) hoses whih re onneted to power steering ooler (port nd strord). 5. Cut two hoses (from ulk hose supplied) of suffiient length to extend from power steering oolers to respetive fittings on priority vlve Elow - Lrge Inverted Flre Fitting - Smll Inverted Flre Fitting 3. Mount priority vlve on rket. Torque olt to 120 l. in. (14 N m). 7A-12 - POWER STEERING

15 6. Connet one end of eh hose to its respetive power steering fluid ooler nd other ends to fittings on priority vlve. Seure with hose lmps. Tighten seurely. 7. Instll return hose (lrge fitting on one end only, from kit) to power steering ontrol vlve. Route hose to priority vlve, ut hose to length, nd onnet to fitting on priority vlve. Seure with hose lmp. Tighten seurely Power Steering Fluid Cooler - Hose - Hose Clmp Power Steering Control Vlve - Hose Fitting - Priority Vlve - Hose - Hose Clmp Priority Vlve - Hose - Hose Clmp POWER STEERING - 7A-13

16 8. Instll pressure hose (fittings on oth ends, from kit) etween power steering ontrol vlve nd lrge inverted flre fitting on priority vlve. (This fitting lotion is mrked with n S. ) Seure with hose lmp. Tighten seurely. 9. Connet No. 1 (strord) engine pressure hose (from pump) to inverted flre fitting mrked y 1 on priority vlve. Connet No. 2 (port) pressure hose (from pump) to inverted flre fitting mrked y 2 on priority vlve. Seure with hose lmps. Tighten seurely Power Steering Control Vlve - Hose Fitting - Priority Vlve - No. 1 (Strord) Pressure Hose - No. 2 (Port) Pressure Hose 10. Seure ll hoses with St-Strps provided Priority Vlve - Hose Fitting 7A-14 - POWER STEERING

17 Filling System with Fluid 11. Fill pump reservoirs with utomti trnsmission fluid (ATF) Dexron ll. 12. Instll nd tighten pump p y turning p lokwise pproximtely 120 degrees. Mintenne Mintenne inspetion is the owner s responsiility nd must e performed t the following intervls: Norml Servie - Every 50 hrs. of opertion or 60 dys (whihever omes first) Severe Servie - Every 25 hrs. of opertion or 30 dys (whihever omes first) NOTE: Opertion in slt wter is onsidered severe servie. 15. Chek ll onnetions nd hose lmps for dequte tightness. Tighten, if loose. 16. Chek ll mounting olts nd tighten if neessry. 17. Be sure to hek reservoir oil level periodilly Cp 13. Fill reservoir ottle to full mrk, then (one t time) slightly loosen pump p to llow fluid to flow from reservoir to pump until pump just strts to overflow, then quikly tighten pump p. Fill ottle reservoir nd repet this proess for the other pump. 14. Doule hek oth ps to ensure they re oth tight POWER STEERING - 7A-15

18 System Flow Digrm 3 2 d 5 e f 4 1 f d Pressure Line e 5 Return Line Grvity Feed Line 1 - Reservoir Bottle nd Brket 2 - Priority Vlve nd Mounting Brket 3 - Power Steering Control Vlve 4 - Power Steering Pump 5 - Power Steering Fluid Cooler - Pressure Hose (Fitting on Both Ends - Supplied in Kit) - Return Hose (Fitting on One End - Supplied in Kit) - Return Hose from Pump (Cut from Bulk Hose Supplied) d - Pressure Hose from Pump e - Return Hose from Pump f - Grvity Feed Hose (Cut from Bulk Hose Supplied) A-16 - POWER STEERING