Dodge Viper SRT-10 (ZB). Manual — part 203
INSTALLATION
The TPS is attached to the throttle body (Fig. 25).
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 26). When indexed cor-
rectly, the TPS can rotate a few degrees to line up
the mounting screw holes with the screw holes in the
throttle body. If the sensor will not rotate into place,
install the sensor with the throttle shaft on the other
side of the socket tangs. The TPS has slight tension
when rotated to align the mounting holes.
(1) Install TPS and mounting screws.
(2) Attach electrical connector to the TPS.
Fig. 26 Throttle Position Sensor—Installation
1 - TANGS
2 - THROTTLE SHAFT
3 - THROTTLE BODY
4 - TPS
14 - 42
FUEL INJECTION
ZB
THROTTLE POSITION SENSOR (Continued)
STEERING
TABLE OF CONTENTS
page
page
STEERING
. . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - HYDRAULIC
FLOW AND PRESSURE . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS . . . . . . . . . . . . 3
POWER STEERING FASTENER TORQUE
. . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STEERING
WARNINGS AND CAUTIONS
WARNING:
POWER
STEERING
FLUID,
ENGINE
PARTS
AND
EXHAUST
SYSTEM
MAY
BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
CAUTION: Do not use any type of automatic trans-
mission fluid in the power steering system. Use
only correct Mopar
T
Power Steering Fluid or equiv-
alent.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HYDRAULIC FLOW
AND PRESSURE
The following procedures are used to test the oper-
ation of the power steering and hydraulic fan sys-
tems on this vehicle. These tests will provide the
gallons per minute (GPM) or flow rate of the power
steering pump along with the maximum relief pres-
sure at given points in the system. Perform the first
test anytime a power steering system problem is
present and the second as necessary once the first
test is completed. These tests will determine if the
power steering pump, hydraulic fan, or power steer-
ing gear is not functioning properly. They will also
determine if the flow coming out of the hydraulic fan
motor is sufficient for the power steering gear. The
following pressure and flow tests are performed using
the Power Steering Analyzer kit 6815 (with appropri-
ate hoses) and Adapter kit 9091. (Refer to 19 -
STEERING - SPECIAL TOOLS)
FLOW AND PRESSURE TEST - AT POWER
STEERING PUMP
(1) Check power steering belt to ensure it is in
good condition and adjusted properly.
(2) Assemble Power Steering Analyzer as follows
(Fig. 1):
(a) Gauge end (inlet) of Flow Meter And Gauge
6800 – Hose 6905, Hose 6713, Adapter Tube 9091-1
(b) Valve end (outlet) of Flow Meter And Gauge
6800 – Hose 6959, Adapter Fitting 9091-3
(3) Unthread pressure hose quick-connect fitting
from power steering pump.
(4) Connect Adapter Tube 9091-1 to pressure fit-
ting on power steering pump.
(5) Connect
power
steering
pressure
hose
to
Adapter Fitting 9091-3.
(6) Open Analyzer test valve completely.
(7) Start engine and allow to idle long enough to
circulate power steering fluid through Analyzer flow
meter and hoses.
(8) Shut off engine and check fluid level; add fluid
as necessary. Repeat Step 7 and Step 8 until air is
bled from system.
(9) Start engine and allow to idle.
(10) Check Analyzer gauge pressure. Initial pres-
sure reading should be 483-690 kPa (70-100 psi). If
pressure is higher, inspect hoses for restrictions and
repair as necessary.
ZB
STEERING
19 - 1
(11) Increase engine speed to 1100 rpm and read
Analyzer Flow Meter. The reading should be 2.6
GPM minimum. If flow reading is below specification,
replace power steering pump.
FLOW AND PRESSURE TEST - AT POWER
STEERING GEAR
NOTE: This test should only be done if necessary
after completing the Pump Flow And Pressure Test
(1) Remove Analyzer from pump and pressure hose
to fan. Reattach pressure hose to pump.
(2) Assemble Power Steering Analyzer as follows
(Fig. 2):
(a) Gauge end (inlet) of Flow Meter And Gauge
6800 – Hose 6959, Adapter Fitting 9091-4
(b) Valve end (outlet) of Flow Meter And Gauge
6800 – Hose 6905, Hose 6713, Adapter Tube 9091-2
(3) Unthread pressure hose tube nut from power
steering gear.
(4) Connect
power
steering
pressure
hose
to
Adapter Fitting 9091-4.
(5) Connect Adapter Tube 9091-2 to power steering
gear.
(6) Open Analyzer test valve completely.
(7) Start engine and allow to idle long enough to
circulate power steering fluid through Analyzer flow
meter and hoses.
(8) Shut off engine and check fluid level; add fluid
as necessary. Repeat Step 7 and Step 8 until air is
bled from system.
(9) Start engine and allow to idle.
(10) Check Analyzer gauge pressure. Initial pres-
sure reading should be 345-552 kPa (50-80 psi). If
pressure is higher, inspect hoses for restrictions and
repair as necessary.
(11) Increase engine speed to 1500 RPM and read
Analyzer Flow Meter. The reading should be 2.4 - 2.8
GPM. If flow reading is below specification, replace
hydraulic fan.
CAUTION: This next step involves testing maximum
fan motor steering relief pressure. Do not leave the
valve closed for more than three seconds.
(12) Close Analyzer valve fully three times for
three seconds each time and record highest pressure
indicated on Analyzer gauge each time. All three
readings must be within fan motor steering relief
pressure specifications.
(13) Completely open test valve and turn steering
wheel to the extreme left and right positions against
stops. Record the highest pressure readings at each
position. If pressure readings are not within 50 psi
from each other, the gear is leaking internally and
must be replaced.
Fig. 1 Analyzer Setup To Test At Pump
1 - HOSE 6959
2 - ADAPTER FITTING 9091-3
3 - FLOW METER AND GAUGE 6800
4 - HOSE 6713
5 - ADAPTER TUBE 9091-1
6 - HOSE 6905
Fig. 2 Analyzer Setup To Test At Gear
1 - HOSE 6905
2 - HOSE 6713
3 - FLOW METER AND GAUGE 6800
4 - ADAPTER FITTING 9091-4
5 - HOSE 6959
6 - ADAPTER TUBE 9091-2
19 - 2
STEERING
ZB
STEERING (Continued)
PUMP OUTLET SPECIFICATIONS
ENGINE
RELIEF
PRESSURE
FLOW RATE
(GPM) @ 1100
RPM
ALL
9653 kPa ± 345
kPa
(1400 psi ± 50 psi)
2.4-2.8 GPM
Minimum @ 1379
kPa (200 psi)
GEAR INLET SPECIFICATIONS
ENGINE
RELIEF
PRESSURE
FLOW RATE
(GPM) @ 1500
RPM
ALL
9653 kPa ± 345
kPa
(1400 psi ± 50 psi)
2.4-2.8 GPM
Minimum @ 1379
kPa (200 psi)
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover POWER STEERING NOISE, STEERING
WHEEL FEEL, and POWER STEERING FLUID.
POWER STEERING NOISE
CONDITION
POSSIBLE CAUSES
CORRECTION
OBJECTIONABLE HISS
OR WHISTLE*
1. Damaged or mispositioned
steering column shaft/coupling dash
panel seal.
1. Reposition or replace steering
column shaft/coupling dash panel seal.
2. Noisy valve in power steering
gear.
2. Replace power steering gear.
RATTLE OR CLUNK
1. Power steering gear loose on
mounting brackets.
1. Inspect power steering gear
mounting bolts. Replace as necessary.
Tighten to the specified torque.
2. Loose tie rod (outer or inner).
2. Check tie rod pivot points for wear.
Replace worn/loose parts as required.
3. Loose lower control arm mounting
(cam) bolts at frame rail.
3. Tighten control arm mounting bolts to
the specified torque values. Perform
wheel alignment.
4. Loose upper control arm-to-pivot
bar mounting nuts.
4. Tighten upper control arm-to-pivot
bar mounting nuts to the specified
torque values.
5. Loose upper control arm pivot
bar-to-frame rail mounting nuts.
5. Tighten upper control arm pivot
bar-to-frame rail mounting nuts to the
specified torque values. Perform wheel
alignment.
6. Power steering fluid pressure
hose touching the body of the
vehicle.
6. Adjust hose to proper position by
loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing.
7. Internal power steering gear
noise.
7. Replace power steering gear.
POPPING NOISE
1. Worn outer tie rod.
1. Replace outer tie rod.
ZB
STEERING
19 - 3
STEERING (Continued)
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