Winnebago 1987-1989 Utility Van Manuals

Manuals and User Guides for Winnebago 1987-1989 Utility Van. We have 1 Winnebago 1987-1989 Utility Van manual available for free PDF download: Service Manual

Winnebago 1987-1989 Utility Van Service Manual (688 pages)

Winnebago 1987-1989 LeSharo; 1987-1989 Phasar; 1987-1989 Utility Van Motor home

Brand: Winnebago | Category: Motorhomes | Size: 26.34 MB

Table of Contents
3
Subsection
4
LE Sharo, Utility Van, and Phasar by Winnebago Industries
7
Term Definitions
8
General Information
9
Subsection
9
Vehicle Identification
11
Specifications
11
Explanation of Data
12
Jacking, Hoisting, and Recovery Towing
13
Conversion Table
15
Capacities and Specifications
18
Vehicles Equipped with J7T-239 Fuel Injected Gasoline Engine
18
Engine Oil Level Check
18
Fluid Changing
19
Oil Draining and Refilling
19
Engine, Gearbox, and Final Drive
19
Oil Filter
19
To Change Final Drive
20
To Change Gearbox Oil (5-Speed)
20
To Change Automatic Transmission Fluid
21
Automatic Transmission Fluid Check
21
Service and Maintenance
22
Chassis Maintenance
22
Chart Code Explanation
22
Chassis Maintenance Schedule
23
Service Operation Descriptions
24
Section C: Fuel System
24
Section E: Cooling System
24
Section F: Automatic
24
2.2 Liter Gasoline Engine (with Bosch Electronic Fuel Injection
27
2.2L Engine 4-Cylinder Aluminum
29
Lubrication Circuit
30
General Information
30
Ghosted View
31
Cylinder Head (Exploded View)
32
Cylinder Block (Exploded View)
33
Engine Identification
34
Special Service Tools
35
Torque Specifications
40
General Specifications
41
Lubrication System
42
Crankshaft Service
42
Reconditioning
42
Engine Removal and Replace
43
Removal Procedure
43
Remove or Disconnect
43
Engine Remove and Replace
44
Preparation for Rebuilding
47
Mounting the Engine to the Dismantling Support
47
Preparing Engine for Installation
48
Clean
48
Inspect and Replace if Necessary
48
Installation Procedure
49
Install or Conned
49
Final Procedures after Installation
50
Adjust
50
Engine Overhaul & Rebuild
52
Special Materials
52
Cleaning Engine in Place
52
Installing Threaded Inserts
52
Engine Overhaul & Rebuild Engine Disassembly
53
Engine Overhaul and Rebuild Cylinder Head
60
Cleaning
61
Measure
61
Inspect
62
Valve Seat Refacing
63
Valve Refacing
63
Valve Installation
63
Engine Overhaul and Rebuild Rocker Shaft
64
Install or Connect
65
Tighten
65
Engine Overhaul and Rebuild
66
Oil Pump
66
Cylinder Block and Related Parts
67
Clean and Inspect
67
Cylinder Block & Related Parts-Clean & Inspect
68
Crankshaft
68
Main and Connecting Rod Bearings
68
Pistons and Sleeves
69
Cylinder Block and Related Parts
70
Connecting Rods
70
Piston Sleeve Assemblies
71
Reassembly
72
Piston Pin Specifications
74
Piston Ring Thickness Specifications
74
Reassemble Cylinder Block Assembly
75
Cylinder Liner Protrusion Measurement
77
Crankshaft Installation
79
Front and Rear Main Bearing Support Side Seals
80
Piston, Connecting Rod and Cylinder Liner Installation
86
Oil Pump and Oil Pan Installation
88
Flywheel/Drive Plate Installation
89
Crankshaft Sprocket and Crankshaft (Vibration Damper) Pulley Installation
90
Cylinder Head Installation
94
Cylinder Head Bolt Tightening
94
Timing Belt Installation
96
Tension Adjustment
98
Rocker Arm Clearance Adjustment (First Procedure)
100
Rocker Arm Clearances (Engine Cold)
101
Rocker Arm Clearance Adjustment Sequence
102
Valve Timing with Theoretical Rocket Arm Clearance of 0.35 MM (0.014 In)
102
Rocker Arm Clearance Adjustment (Second Procedure)
103
Rocker Arm Clearance
105
Final Assembly
106
Belt Tensioning Procedure
107
Checking Method
107
Timing Belt
107
Power Steering Belt:
107
Engine Water Pump
109
Remove and Replace
109
Installation
109
Oil Pressure
110
Checking Procedure
110
Ignition System
111
Operating Principles
111
Magnetic Position Sensor (P)
111
Vacuum Sensor (C)
111
Connector Identification
112
Ignition Timing
112
Distributor (M)
112
Diagnostics
113
Magnetic Position Sensor (P) (T.D.C. Sensor)
113
Fuel System
114
Engine Fuel System
116
Engine Fuel System General
117
System Description
117
Engine Fuel System (Fuel/L-Electronic System Diagram)
119
System Components
119
Fuel Pump
120
Fuel Pressure Regulator
121
Fuel Injectors
121
Airflow Meter
122
Throttle Plate & Throttle Position
122
Oxygen Sensor
123
Cold Start Injector
123
Thermo-Time Coolant Switch
124
Auxiliary Air Regulator
124
Coolant Temperature Sensor
125
Atmospheric Pressure Sensor
125
Fast Idle Solenoid
125
Idle Speed Controls
125
Fast Idle Diagram
126
Tachometric Relay (Vehicles with Automatic Transmission)
127
Full Enrichment Time Delay System (Vehicles with S-Speed Transmission)
127
Component Testing
128
Thermo-Time Coolant Switch Tests
128
First Test Procedure
128
Second Test Procedure
129
Supplementary Air Regulator Heater Test
130
Supplementary Air Regulator Wire Harness Test
130
Coolant Temperature Sensor (CTS) Test
131
Electrical Test
131
Component Replacement
132
Coolant Temperature Sensor Replacement
132
Thermo-Time Coolant Switch Replacement
132
Oxygen (O2) Sensor Replacement
133
Electronic Controlunit (ECU) Replacement (Located under Passenger Seat)
133
Control Relay Replacement
133
Air Intake System Leak Test
133
Fuel System, Vacuum Hoses and PCV System
134
Fuel System Test
135
Fuel Pressure Test
135
Fuel Pump Output Test
135
Injector Test
136
Wiring Diagram
137
Full Enrichment Time Delay System (5-Speed)
138
Wire Harness Connections
139
ECU (Electronic Control Unit) Connector Pin Reference
140
Control Relay Connector
140
Control Relay Pin Reference
140
General Information
140
Diagnostic Plugs
141
(D1) 6-Connector Plug
141
(D2)-15-Connector Plug
141
Throttle Position Switch (T.P.S.) Connector
142
Throttle Position Switch (T.P.S.) Operational Test
142
Throttle Position Switch Adjustment
142
Airflow Meter Pin Reference
143
Integrator Voltage
144
Lean Mixture
144
Rich Mixture
144
Functional Test (Method 1)
146
Functional Test (Method 2)
150
Before Starting Engine
151
When Starting Engine or Just after Engine Start
151
Engine Running and Warm
152
Engine off and Hot
153
Functional Test for Winnebago H-Body Equipped with 5-Speed Manual Transmission
154
Idle Speed Adjustment
157
Airflow Meter Bypass and Adjustment
157
Emission Control System Diagram
159
System Operation
160
Emission Hose Routing
161
Fuel Tank Gauge Sending Unit
162
Remove and Replace Fuel Tank
162
Reinstall Fuel Tank
162
Sending Unit Removal
163
Sending Unit Installation
163
Sending Unit Testing
163
Roll over Valve
164
Purpose and Operation of the Valve
164
Electrical
165
Special Tools
167
Fuses-Automotive
168
Circuit Breaker
168
General
168
Auxiliary Battery
169
Location
169
Dual Battery Switch
169
Engine Coolant Temperature Switch
170
Location on Engine
170
Engine Oil Pressure Switch
171
Checking
171
Steering Column Switches
172
Removal
172
Windshield Wipers
173
Mechanism Removal
173
Special Point Concerning Reassembly
173
Bosch 5-Prong Relay
174
Fuel Tank Sending Unit
175
Testing
175
Instrument Cluster
176
Layout
176
Instrument Panel
176
Alternator Exploded View
179
Operation-Diagnosis
180
Alternator with Built-In Regulator
180
Diagnosing Problems
180
Repair
182
Removing Regulator
182
Starter
183
Paris-Rhone D10E 88
184
Starting Drive Mechanism
185
Adjusting the Starting Drive Mechanism Solenoid Linkage Fork
185
Brush Replacement
186
Solenoid Replacement
186
Rear Wiring Harness
187
Routing
187
Wire Harness
187
Wire Harness
188
Engine and Front Harness Routing
188
Wiring Diagram Index
190
Wire Assembly Identification
191
1987 Production
192
Wire Identification
193
Chassis Assembly Wires
193
Winnebago Assembly Wires
193
Component Locations
194
Harness Codes
196
Wire Color Codes
196
1988 Production
215
Connector Locations
216
Cooling System
241
Special Tools
243
Theory of Operation
244
Thermostat
244
Electric Cooling Fan Operation
244
Relay Locations
244
Anti-Freeze Mixture Strength Checking
245
Сooling Circuit
246
Сhecking for Leaks
246
Cooling Circuit Checking for Leaks
246
Сhecking Coolant Bottle
247
Сap Calibration
247
Cooling System - Refilling and Bleeding
248
Oil in Cooling Circuit
249
General Information
253
Diagnostic
275
Components
310
Transmission Rebuild Exploded View
330
Disassembly
333
Separating the Casings
333
Transmission Rebuild Clean and Inspect
339
Gear Section Casing
340
Fluid Pump
340
Feed Hub-Sealing Rings
341
Brakes
341
Clutches
341
Cup with Crimped Spring
342
Seal
342
Valve Body
342
Free Wheel
342
Transmission Rebuild Reassembly
343
Adjusting F2 Piston
345
Checking the Operation of the Piston
345
Check that the Assembly Is Correct
346
Brake F1
347
Operating Check
349
Adjusting the Reverse Gear Train
350
Coupling Transmission to Final Drive
355
Adjusting the End Float
355
Final Reassembly Procedure
358
Final Drive Rebuild
359
Tightening Torques
359
Differential/Intermediate Case Gasket
360
Repair Procedure
360
Dismantling
362
Separator Housing
363
Final Drive Rebuild Disassembly
364
Removing the Final Drive Pinion Remove
364
Final Drive Rebuild Clean and Inspect
368
Final Drive Rebuild Reassembly
369
Step-Down Drive Shaft
369
Output Shaft
369
Reassembling the Final Drive Pinion
372
Assemble
373
1St Type
373
2Nd Type
373
Differential
374
Adjusting Backlash
375
Adjusting Differential Bearing Pre-Load
377
Reassembling the Separator Housing
380
Final Drive Oil Cooling System
382
Principle of Operation
382
Final Drive Oil Change
383
Electrical Troubleshooting
385
Troubleshooting
386
If the Pump Does Not Run
386
If the Pump Keeps Running and Does Not Stop
386
External Seal Replacement
387
Differential Seal
387
Refitting
388
Speedometer Shaft Seal
389
Removing
389
5-Speed Gearbox (Transaxle)
391
Subsection 1 General Information
391
Subsection 3 Rebuild
391
Starter Mount/Clutch Housing Cracks
407
Special Features
407
Anaerobic Sealant
408
Removal and Installation
410
5-Speed Gearbox Disassembly
411
Type "NL" 5-Speed Transmissions
411
Gear Disassembly/Reassembly
417
5-Speed Gearbox Reassembly
419
Transmission Reassembly
419
Rebuild Disassembly
420
Removing the Final Drive Pinion
421
Rebuild Clean and Inspect
424
Rebuild Final Drive Assembly
425
Clutch Housing Thrust Bearing Tube
425
Refining the Final Drive Pinion
427
Refit
428
Primary Shaft Assembly
433
Secondary Shaft Assembly
438
Installing the Step-Down Gear Onto the Secondary Shaft
438
Step-Down Gear Thickness
438
Replacing a 21.4 MM Step-Down Gear
438
Secondary Shaft
441
1St Arrangement
441
2Nd Arrangement
441
1St; 2Nd Type of Assembly
444
Rebuild Final Assembly
445
Section H: Clutch
459
Subsection 1 General Information
459
Subsection 2 Pressure Plate - Disc
459
Subsection 3 Flywheel
459
Clutch Cable
467
Section I: Brakes
469
Subsection 1 Specifications
469
Master Cylinder
476
Brake Servo
477
Front Brake Pads
480
Front Brake Calipers
484
Rear Brake Shoes
487
Brake Limiter
491
Handbrake
493
Specifications
505
Front Axle Alignment
506
Stub Axle Carriers
522
Steering Box
528
Power Steering Pump
532
Drive Shaft
541
Specifications
552
Specifications
553
Subsection 2 Front Struts
561
Rear Shock Absorbers
572
Specifications
576
Dashboard
580
Airflow Distribution Cable
583
Heater Valve and Fresh Air Door Cable
584
Airflow Distributor
585
Heater Valve
586
Fan Motor
597
Servicing the Alc System
600
Electronic Speed Control (Cruise)
621
Front End Drawings Paint Codes
647
Windshield
658
Cab Door Latch Mechanism
661
Cab Window and Cranks - Remove and Replace
665
Frame Dimension
673

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Winnebago 1987-1989 Utility Van Manuals

Winnebago 1987-1989 Utility Van Service Manual (688 pages)

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