Disassembly and Assembly

Disassembly

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

Fig. 7 Exploded View Of Power Steering Pump:

3. Using special service tool No. 09278-54012 or equivalent, remove the pulley nut and pulley, Fig. 7.
4. Remove three bolts, reservoir tank, and O-ring.
5. Remove pressure port union and O-ring.
6. Remove flow control valve and spring.
7. Remove two bolts and rear housing.
8. Remove cam ring, rotor, vane plates, straight pins, and gasket.
9. Using snap ring pliers, remove snap ring, then using a press, press out shaft with bearing.
10. Using a plastic hammer, tap out side plate and wave washer, then remove two O-rings.

Inspection

1. Measure oil clearance of shaft and bushing using suitable measuring tools. Maximum clearance is .0028 inch.
2. Inspect rotor and vane plates using suitable measuring tools. Minimum height is .335 inch, minimum thickness is .0539 inch and minimum length is .5894 inch.

Fig. 2 Power Steering System Rotor & Cam Ring Identification Marks:

Fig. 8 Rotor & Cam Ring Identification Chart:

3. Using suitable feeler gauge, measure clearance between the rotor groove and vane plate. Maximum clearance is .0016 inch. If clearance is not as specified, replace vane plate and/or rotor with one having the same mark stamped on the cam ring, Figs. 2 and 8.
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. Measure the flow control spring free length. If spring free length is not 1.30 inch, replace spring.
6. Using special service tool No. 09631-10030 or equivalent, drive out oil seal.
7. Using a 24mm socket and a hammer, drive in new oil seal.
8. Using a press, remove old ball bearing and install new ball bearing to pump shaft.

Assembly

1. Coat all sliding surfaces with power steering fluid prior to assembly.
2. Using a press and special service tool No. 09608-30012 or equivalent, press in the shaft.
3. Using snap ring pliers, install snap ring.
4. Install cam ring, rotor, vane plates, and rear side plate.
5. Install wave washer so that its protrusions fit into slots in rear side plate.
6. Install rear housing and two bolts. Torque bolts to 12 ft. lb.
7. Ensure shaft rotates smoothly without abnormal noise.
8. Temporarily install pulley nut and check the rotating torque. Rotating torque should be no more than 2.2 in. lb.
9. Install spring, flow control valve, and pressure port union. Torque pressure port union to 61 ft. lb.
10. Install O-ring, reservoir tank, and bolts. Torque front side bolts to 9 ft. lb. and rear side bolts to 12 ft. lb.
11. Install pump pulley to shaft, then install set nut. Torque nut to 32 ft. lb.
12. Install steering pump.