Disassembly and Assembly

Disassembly

1. Remove steering pump.
2. Mount pump in a suitable vise.

Power Steering Pump:

3. Using special service tool No. 09960-10010 or equivalent, remove pulley set nut and pulley, Fig. 7
4. Remove three reservoir retaining bolts, O-ring from reservoir then reservoir.
5. Remove pressure port union, O-ring from union and flow control valve and spring.
6. Remove two rear housing bolts, then rear housing.
7. Remove cam ring, rotor, vane plates, straight pins, then gasket.
8. Remove snap ring, wind vinyl tape on serrated part of vane pump shaft, then using a press, press out shaft with bearing.
9. Using a plastic hammer, tap out side plate and wave washer, then remove two O-rings.

Inspection

1. Using suitable calipers and a micrometer, measure oil clearance of shaft and bushing. Standard clearance is .0012-.0020 inch, maximum clearance is .0028 inch. If clearance is more than maximum, replace pump.
2. Using a suitable micrometer, measure height, thickness and length of vane plates. Minimum height is .339 inch, minimum thickness is .0051 inch and minimum length is .5902.
3. Using a feeler gauge, measure clearance between rotor groove and vane plate. Maximum clearance is .0012 inch. If measurement exceeds maximum, replace vane plate and/or rotor with one having same mark stamped on cam ring, see below:

Rotor and Cam Ring No. Vane Length mm.

None 14.999-15.001
1 14.997-14.999
2 14.995-14.997
3 14.993-14.995
4 14.991-14.993

4. Inspect flow control valve as follows:
a. Coat valve with power steering fluid and ensure it falls smoothly into valve hole by its own weight.
b. Close one of the holes and apply 57-71 psi compressed air into opposite side and confirm that air does not come out from end holes.
c. If necessary, replace valve with one having the same letter as inscribed on front housing (A through F).
5. Using a scale, inspect flow control spring. Free length of spring should be 1.30 inch. If not within specifications, replace spring.
6. If necessary to replace oil seal, tap out seal, coat with power steering fluid, then press in with 24 mm socket wrench.
7. If necessary to replace bearing, press out old bearing with a press, replace snap ring, then press in new bearing.

Assembly

1. Coat all sliding surfaces with fresh power steering fluid.
2. Wind vinyl tape on serrated part of vane shaft, using service tool No. 09608-30012, press in shaft, then install new snap ring.
3. Using a plastic hammer, drive two straight pins into front housing. Align holes of cam ring and straight pins, the insert cam ring with inscribed mark facing outward. Install rotor to shaft with inscribed mark facing outward.
4. Install ten vane plates with round end facing outward, then gasket.
5. Install wave washer so its protrusions fit into slots on rear side plate.
6. Install rear housing and torque two bolts to 12 ft. lb.
7. Check that shaft rotates smoothly without abnormal noise. Temporarily install pulley nut and check rotating torque. Rotating torque should be 2.2 ft. lb. or less.
8. Coat new O-ring with fresh power steering fluid and install in pressure port union.
9. Install spring and flow control valve to front housing. Ensure flow control valve is installed in correct direction.
10. Install and torque pressure port union to 61 ft. lb.
11. Coat new O-ring with fresh power steering fluid and install in reservoir tank.
12. Install reservoir tank with three bolts. Torque front side bolt to 9 ft. lb. and rear side bolts to 12 ft. lb.
13. Install pump pulley and set nut to shaft. Using service tool No. 09960-10010, torque set nut to 32 ft. lb.