Overhaul

DISASSEMBLY

CAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly.

NOTE:
- Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a solvent.
- Always replace the O-rings and rubber seals with new ones before assembly.
- Apply recommended power steering fluid to the parts indicated in the assembly procedures.
- Do not allow dust, dirt, or other foreign materials to enter the power steering system.
- Replace the pump as an assembly if the parts indicated with asterisk (*) are worn or damaged.

1. Drain the fluid from the pump.





2. Hold the steering pump a vise with son jaws, hold the pulley with the special tool, and remove the pulley nut and pulley.

CAUTION: Be careful not to damage the pump housing with the jaws of the vise.

NOTE: Pulley nut has left-hand threads.

3. Remove the snap ring, then remove the sub-valve from the pump housing outlet port.
4. Remove the inlet joint and O-ring.
5. Remove the flow control valve cap, O-rings, spring and flow control valve.
6. Remove the inlet joint and O-ring.
7. Remove the pump cover and O-ring.
8. Remove the pump cam ring, pump rotor, pump vanes, side plate and preload spring.
9. Remove the O-rings from the side plate.
10. Remove the circlip, then remove the pump drive shaft by tapping the shaft end with the plastic hammer.
11. Remove the pump seal spacer and pump seal.





INSPECTION

Flow Control Valve
1. Check the flow control valve for wear, burrs, and other damage to the edges of the grooves in the valve.
2. Inspect the bore and the flow control valve for scratches and wear.





3. Slip the valve back in the pump, and check that it moves in and out smoothly. If OK, go to step 4; if not, replace the pump as an assembly. The flow control valve is not available separately.





4. Attach a hose to the end of the valve as shown.





5. Submerge the valve in a container of power steering fluid or solvent, and blow in the hose. If air bubbles leak through the valve at less than 100 kPa (14.2 psi), repair it as follows.
6. Hold the bottom end of the valve with a open end wrench.





7. Unscrew the seat in the top end of the valve, and remove any shims, the relief check ball, relief valve and relief valve spring.
8. Clean all the parts in solvent, dry them off, then reassemble and retest the valve. If the flow control valve tests OK, reinstall it in the pump. If the flow control valve still leaks air, replace the pump as an assembly. The flow control valve is not available separately.

NOTE: If necessary, relief pressure is adjusted at the factory by adding shims under the check ball seat. If you found shims in your valve, be sure you reinstall as many as you took out.

Power Steering Pump Ball Bearing Inspection:

Inspection/Replacement
1. Inspect the ball bearing by rotating the outer race slowly. If any play or roughness is felt, replace the ball bearing.





2. Remove and discard the ball bearing using the special tool and a press as shown.
3. Install the new ball bearing using the special tool and a press as shown.

ASSEMBLY
1. Coat the lip of the new oil seal with steering grease.





2. Install the new oil seal in the pump housing by hand, then install the pump seal spacer.

NOTE: Insert the oil seal with its grooved side facing in.

3. Install the pump drive shaft assembly with the special tool.
4. Install the 38 mm circlip with its tapered side facing out.





5. Coat the side plate grooves with the recommended power steering fluid, then position the 16.8 x 1.9 mm and 54 x 1.9 mm O-rings on the side plate.





6. Install the preload spring in the pump housing.
7. Set the 4.5 x 49.8 mm roller in the 4.5 mm hole in the pump housing.
8. Set the side plate over the roller, and install it on the pump housing.
9. Set the 5 x 26.8 mm roller in the 5 mm hole in the side plate.
10. Assemble pump rotor to the drive shaft with the "a" mark on the rotor facing upward.





11. Set the 10 vanes in the grooves in the rotor.

NOTE: Be sure that the round ends of the vanes are in contact with the sliding surface of the cam ring.





12. Set the pump cam ring over the two rollers with the "8" mark on the cam ring upward.
13. Apply clean power steering fluid to the vanes and cam ring.





14. Install the 68.5 x 1.9 mm O-ring on the numb cover.
15. Align the roller set holes in the pump cover with the rollers.
16. Align the projection on the pump housing and the projection on the pump cover, and tighten the four bolts.





17. Set the 13 x 1.9 mm O-ring on the inlet joint.
18. Install the inlet joint on the pump housing.





19. Align the pin of sub valve with the oil passage in pump housing, and push down the sub valve. Fix the sub valve with the snap ring.
20. Rotate the pump drive shaft manually, and make sure the pump drive shaft rotates smoothly.





21. Coat the new O-rings with clean power steering fluid, then install them in the housing grooves.
22. Coat the flow control valve with clean power steering fluid.
23. Install the flow control valve, spring and control valve cover on the pump housing.
24. Tighten the three control cover bolts.
25. Hold the steering pump in a vise with sod jaws.

CAUTION: Be careful not to damage the pump housing with the jaws of the vise.





26. Install the pump pulley as shown, then install the pulley nut.





27. Hold the pulley with the special tool, and tighten the pulley nut.
28. Check that the pump turns smoothly by turning the pulley.