Power Steering Pump - Flushing/Replacement
87isuzu03BULLETIN NUMBER ISSUE DATE GROUP
SB87-10-002 September 15, 1987 STEERING
1986 P'UP (KB) AND TROOPER II (KT) POWER STEERING PUMP REPLACEMENT AND SYSTEM FLUSHING (4ZD1 ENGINE)
VEHICLES AFFECTED
1986 P'UP (KB) and Trooper II (KT) models with 4ZD1 engine and power steering.
SERVICE INFORMATION
An improved design power steering pump is available in kit form for field installation.
If the original equipment pump failed due to internal damage, contamination may have entered the system lines and gearbox. To prevent a repeat failure of the new pump, flush the power steering system as described in this Service Bulletin after the new pump kit is installed.
SERVICE PROCEDURE
1. Remove the suction and return lines from the power steering fluid reservoir. Let the lines and
FIGURE 1:
reservoir drain into an appropriate container. Discard this fluid.
2. Remove the failed pump from the engine as described in the appropriate Workshop Manual.
3. Remove the reservoir, the section hoses and the suction pipe from the vehicle. Clean these parts thoroughly.
4. Install the power steering pump kit (part No. 8-94472-978-0). This kit (Figure 1) contains:
a. A replacement pump, pulley, pulley nut and adjustment plate.
b. A replacement suction hose and pressure hose to attach to the pump (the suction pipe and one original suction hose are reused).
FIGURE 2:
c. A new clip, bolt and nut to secure the pressure hose (Figure 2).
5. Install the reservoir, suction pipe and one original suction hose. Do not install the return line onto the reservoir at this time; instead, plug the reservoir fitting so that the reservoir will hold fluid.
6. Lift the front axle. Place the open end of the return line in an appropriate drain container.
7. With the engine off, turn the wheels all the way to the right and then to the left. Repeat until no fluid drains from the return line.
8. Fill the reservoir with fresh power steering fluid.
9. Start the engine and run it at idle. Turn the wheels all the way to the right and then to the left. Continue
turning the wheels lock-to-lock until fluid drains from the return line. Check the reservoir fluid level and top up, if necessary.
10. Repeat Step 9 until 3 liters of fresh power steering fluid have been flushed through the system. Do not re-use the drained fluid.
11. Turn the engine off. Continue turning the wheels lock-to-lock until no fluid drains from the return line.
12. Unplug the return line fitting on the reservoir and connect the return line. Fill the reservoir with fresh fluid.
13. Bleed air out of the power steering system as described in the appropriate Workshop Manual. When bleeding is complete, top up the reservoir as required.
PARTS INFORMATION
Part No. Description
8-94472-978-0 Power Steering Pump Service Kit
Each kit contains:
8-94408-785-2 Pump Assy.
8-94438-864-1 Adjust Plate
8-94467-466-0 Pulley
8-94139-015-0 Pulley Nut
8-94462-460-0 Pressure Hose
8-94462-470-1 Bracket
9-09716-061-0 Clip
0-28210-616-0 Bolt
0-91150-106-0 Nut
8-94471-683-0 Suction Hose
FLAT RATE MANUAL UPDATE INFORMATION