Table Of Contents - Winnebago 1987-1989 LeSharo Service Manual

Table of Contents

Table Of Contents3
Subsection4
Le Sharo, Utility Van, And Phasar By Winnebago Industries7
Term Definitions8
General Information9
Vehicle Identification11
Specifications11
Explanation Of Data12
Jacking, Hoisting, And Recovery Towing13
Conversion Table15
Capacities And Specifications18
Vehicles Equipped With J7T-239 Fuel Injected Gasoline Engine18
Engine Oil Level Check18
Fluid Changing19
Oil Draining And Refilling19
Engine, Gearbox, And Final Drive19
Oil Filter19
To Change Final Drive20
To Change Gearbox Oil (5-Speed)20
To Change Automatic Transmission Fluid21
Automatic Transmission Fluid Check21
Service And Maintenance22
Chassis Maintenance22
Chart Code Explanation22
Chassis Maintenance Schedule23
Service Operation Descriptions24
Section C: Fuel System24
Section E: Cooling System24
Section F: Automatic24
2.2 Liter Gasoline Engine (With Bosch Electronic Fuel Injection27
2.2L Engine 4-Cylinder Aluminum29
Lubrication Circuit30
Ghosted View31
Cylinder Head (Exploded View)32
Cylinder Block (Exploded View)33
Engine Identification34
Special Service Tools35
Torque Specifications40
General Specifications41
Lubrication System42
Crankshaft Service42
Reconditioning42
Engine Removal And Replace43
Removal Procedure43
Remove Or Disconnect43
Engine Remove And Replace44
Preparation For Rebuilding47
Mounting The Engine To The Dismantling Support47
Preparing Engine For Installation48
Clean48
Inspect And Replace If Necessary48
Installation Procedure49
Install Or Conned49
Final Procedures After Installation50
Adjust50
Engine Overhaul & Rebuild52
Special Materials52
Cleaning Engine In Place52
Installing Threaded Inserts52
Engine Overhaul & Rebuild Engine Disassembly53
Engine Overhaul And Rebuild Cylinder Head60
Cleaning61
Measure61
Inspect62
Valve Seat Refacing63
Valve Refacing63
Valve Installation63
Engine Overhaul And Rebuild Rocker Shaft64
Install Or Connect65
Tighten65
Engine Overhaul And Rebuild66
Oil Pump66
Cylinder Block And Related Parts67
Clean And Inspect67
Cylinder Block & Related Parts-Clean & Inspect68
Crankshaft68
Main And Connecting Rod Bearings68
Pistons And Sleeves69
Connecting Rods70
Piston Sleeve Assemblies71
Reassembly72
Piston Pin Specifications74
Piston Ring Thickness Specifications74
Reassemble Cylinder Block Assembly75
Cylinder Liner Protrusion Measurement77
Crankshaft Installation79
Front And Rear Main Bearing Support Side Seals80
Piston, Connecting Rod And Cylinder Liner Installation86
Oil Pump And Oil Pan Installation88
Flywheel/Drive Plate Installation89
Crankshaft Sprocket And Crankshaft (Vibration Damper) Pulley Installation90
Cylinder Head Installation94
Cylinder Head Bolt Tightening94
Timing Belt Installation96
Tension Adjustment98
Rocker Arm Clearance Adjustment (First Procedure)100
Rocker Arm Clearances (Engine Cold)101
Rocker Arm Clearance Adjustment Sequence102
Valve Timing With Theoretical Rocket Arm Clearance Of 0.35 Mm (0.014 In)102
Rocker Arm Clearance Adjustment (Second Procedure)103
Rocker Arm Clearance105
Final Assembly106
Belt Tensioning Procedure107
Checking Method107
Timing Belt107
Power Steering Belt:107
Engine Water Pump109
Remove And Replace109
Installation109
Oil Pressure110
Checking Procedure110
Ignition System111
Operating Principles111
Magnetic Position Sensor (P)111
Vacuum Sensor (C)111
Connector Identification112
Ignition Timing112
Distributor (M)112
Diagnostics113
Magnetic Position Sensor (P) (T.d.c. Sensor)113
Fuel System114
Engine Fuel System116
Engine Fuel System General117
System Description117
Engine Fuel System (Fuel/L-Electronic System Diagram)119
System Components119
Fuel Pump120
Fuel Pressure Regulator121
Fuel Injectors121
Airflow Meter122
Throttle Plate & Throttle Position122
Oxygen Sensor123
Cold Start Injector123
Thermo-Time Coolant Switch124
Auxiliary Air Regulator124
Coolant Temperature Sensor125
Atmospheric Pressure Sensor125
Fast Idle Solenoid125
Idle Speed Controls125
Fast Idle Diagram126
Tachometric Relay (Vehicles With Automatic Transmission)127
Full Enrichment Time Delay System (Vehicles With S-Speed Transmission)127
Component Testing128
Thermo-Time Coolant Switch Tests128
First Test Procedure128
Second Test Procedure129
Supplementary Air Regulator Heater Test130
Supplementary Air Regulator Wire Harness Test130
Coolant Temperature Sensor (Cts) Test131
Electrical Test131
Component Replacement132
Coolant Temperature Sensor Replacement132
Thermo-Time Coolant Switch Replacement132
Oxygen (O2) Sensor Replacement133
Electronic Controlunit (Ecu) Replacement (Located Under Passenger Seat)133
Control Relay Replacement133
Air Intake System Leak Test133
Fuel System, Vacuum Hoses And Pcv System134
Fuel System Test135
Fuel Pressure Test135
Fuel Pump Output Test135
Injector Test136
Wiring Diagram137
Full Enrichment Time Delay System (5-Speed)138
Wire Harness Connections139
Ecu (Electronic Control Unit) Connector Pin Reference140
Control Relay Connector140
Control Relay Pin Reference140
Diagnostic Plugs141
(D1) 6-Connector Plug141
(D2)-15-Connector Plug141
Throttle Position Switch (T.p.s.) Connector142
Throttle Position Switch (T.p.s.) Operational Test142
Throttle Position Switch Adjustment142
Airflow Meter Pin Reference143
Integrator Voltage144
Lean Mixture144
Rich Mixture144
Functional Test (Method 1)146
Functional Test (Method 2)150
Before Starting Engine151
When Starting Engine Or Just After Engine Start151
Engine Running And Warm152
Engine Off And Hot153
Functional Test For Winnebago H-Body Equipped With 5-Speed Manual Transmission154
Idle Speed Adjustment157
Airflow Meter Bypass And Adjustment157
Emission Control System Diagram159
System Operation160
Emission Hose Routing161
Fuel Tank Gauge Sending Unit162
Remove And Replace Fuel Tank162
Reinstall Fuel Tank162
Sending Unit Removal163
Sending Unit Installation163
Sending Unit Testing163
Roll Over Valve164
Purpose And Operation Of The Valve164
Electrical165
Special Tools167
Fuses-Automotive168
Circuit Breaker168
General168
Auxiliary Battery169
Location169
Dual Battery Switch169
Engine Coolant Temperature Switch170
Location On Engine170
Engine Oil Pressure Switch171
Checking171
Steering Column Switches172
Removal172
Windshield Wipers173
Mechanism Removal173
Special Point Concerning Reassembly173
Bosch 5-Prong Relay174
Fuel Tank Sending Unit175
Testing175
Instrument Cluster176
Layout176
Instrument Panel176
Alternator Exploded View179
Operation-Diagnosis180
Alternator With Built-In Regulator180
Diagnosing Problems180
Repair182
Removing Regulator182
Starter183
Paris-Rhone D10E 88184
Starting Drive Mechanism185
Adjusting The Starting Drive Mechanism Solenoid Linkage Fork185
Brush Replacement186
Solenoid Replacement186
Rear Wiring Harness187
Routing187
Wire Harness187
Engine And Front Harness Routing188
Wiring Diagram Index190
Wire Assembly Identification191
1987 Production192
Wire Identification193
Chassis Assembly Wires193
Winnebago Assembly Wires193
Component Locations194
Harness Codes196
Wire Color Codes196
1988 Production215
Connector Locations216
Cooling System241
Theory Of Operation244
Thermostat244
Electric Cooling Fan Operation244
Relay Locations244
Anti-Freeze Mixture Strength Checking245
Сooling Circuit246
Сhecking For Leaks246
Cooling Circuit Checking For Leaks246
Сhecking Coolant Bottle247
Сap Calibration247
Cooling System - Refilling And Bleeding248
Oil In Cooling Circuit249
Diagnostic275
Components310
Transmission Rebuild Exploded View330
Disassembly333
Separating The Casings333
Transmission Rebuild Clean And Inspect339
Gear Section Casing340
Fluid Pump340
Feed Hub-Sealing Rings341
Brakes341
Clutches341
Cup With Crimped Spring342
Seal342
Valve Body342
Free Wheel342
Transmission Rebuild Reassembly343
Adjusting F2 Piston345
Checking The Operation Of The Piston345
Check That The Assembly Is Correct346
Brake F1347
Operating Check349
Adjusting The Reverse Gear Train350
Coupling Transmission To Final Drive355
Adjusting The End Float355
Final Reassembly Procedure358
Final Drive Rebuild359
Tightening Torques359
Differential/Intermediate Case Gasket360
Repair Procedure360
Dismantling362
Separator Housing363
Final Drive Rebuild Disassembly364
Removing The Final Drive Pinion Remove364
Final Drive Rebuild Clean And Inspect368
Final Drive Rebuild Reassembly369
Step-Down Drive Shaft369
Output Shaft369
Reassembling The Final Drive Pinion372
Assemble373
1St Type373
2Nd Type373
Differential374
Adjusting Backlash375
Adjusting Differential Bearing Pre-Load377
Reassembling The Separator Housing380
Final Drive Oil Cooling System382
Principle Of Operation382
Final Drive Oil Change383
Electrical Troubleshooting385
Troubleshooting386
If The Pump Does Not Run386
If The Pump Keeps Running And Does Not Stop386
External Seal Replacement387
Differential Seal387
Refitting388
Speedometer Shaft Seal389
Removing389
5-Speed Gearbox (Transaxle)391
Subsection 1 General Information391
Subsection 3 Rebuild391
Starter Mount/Clutch Housing Cracks407
Special Features407
Anaerobic Sealant408
Removal And Installation410
5-Speed Gearbox Disassembly411
Type "Nl" 5-Speed Transmissions411
Gear Disassembly/Reassembly417
5-Speed Gearbox Reassembly419
Transmission Reassembly419
Rebuild Disassembly420
Removing The Final Drive Pinion421
Rebuild Clean And Inspect424
Rebuild Final Drive Assembly425
Clutch Housing Thrust Bearing Tube425
Refining The Final Drive Pinion427
Refit428
Primary Shaft Assembly433
Secondary Shaft Assembly438
Installing The Step-Down Gear Onto The Secondary Shaft438
Step-Down Gear Thickness438
Replacing A 21.4 Mm Step-Down Gear438
Secondary Shaft441
1St Arrangement441
2Nd Arrangement441
1St; 2Nd Type Of Assembly444
Rebuild Final Assembly445
Section H: Clutch459
Subsection 2 Pressure Plate - Disc459
Subsection 3 Flywheel459
Clutch Cable467
Section I: Brakes469
Subsection 1 Specifications469
Master Cylinder476
Brake Servo477
Front Brake Pads480
Front Brake Calipers484
Rear Brake Shoes487
Brake Limiter491
Handbrake493
Front Axle Alignment506
Stub Axle Carriers522
Steering Box528
Power Steering Pump532
Drive Shaft541
Subsection 2 Front Struts561
Rear Shock Absorbers572
Dashboard580
Airflow Distribution Cable583
Heater Valve And Fresh Air Door Cable584
Airflow Distributor585
Heater Valve586
Fan Motor597
Servicing The Alc System600
Electronic Speed Control (Cruise)621
Front End Drawings Paint Codes647
Windshield658
Cab Door Latch Mechanism661
Cab Window And Cranks - Remove And Replace665
Frame Dimension673