Disassembly and Assembly

DISASSEMBLY

NOTICE: When using a vise, do not overtighten it.

1. Measure power steering vane pump rotating torque, as follows:
a. Check the pump rotates smoothly without abnormal noise.





b. Using a torque wrench, check the pump rotating torque.
Rotating torque: 0.3 Nm (2.4 inch lbs.) or less.
2. Remove vane pump pulley. Using Special Service Tool (SST) 09960 - 10010 (09962 - 01000, 09963 - 01000) or equivalents, to stop the pulley rotating, remove the pulley set nut.
3. Remove oil reservoir, as follows:
a. Remove the three bolts.
b. Remove the O-ring from the reservoir.
4. Remove pressure port union, flow control valve and spring. Remove the O-ring from the union.
5. Remove rear housing. Remove the two bolts.
6. Remove cam ring, vane pump rotor and ten vane plates.

NOTICE: Take care not to drop the plates.

7. Remove two straight pins.
8. Remove gasket.
9. Remove vane pump shaft with bearing, as follows:
a. Using snap ring pliers, remove the snap ring from the front housing.





b. Wind vinyl tape on the serrated part of the shaft.
c. Using a press, press out the shaft with the bearing.
10. Remove side plate and the wave washer, as follows:





a. Using a plastic hammer, tap out the plate and wave washer.
b. Remove the two O-rings from the rear housing.

INSPECTION





1. Measure oil clearance between vane pump shaft and bushing. Using a micrometer and caliper gauge, measure the oil clearance.
Clearance:
Standard: 0.03 - 0.05 mm (0.0012 - 0.0020 inch).
Maximum: 0.07 mm (0.0028 inch).
If it is more than maximum, replace the front housing and vane pump shaft.
2. Inspect vane pump rotor and the vane plates, as follows:





a. Using a micrometer, measure the height, thickness and length of the ten vane plates.
Minimum:
Height: 8.6 mm (0.339 inch).
Thickness: 1.40 mm (0.0551 inch).
Length: 14.99 mm (0.59021 inch).





b. Using a feeler gauge, measure the clearance between the rotor groove and vane plate. If it is more than maximum, replace the vane plate and/or rotor with one having the same mark stamped on the cam ring.
Maximum clearance: 0.04 mm (0.0016 inch).





c. The inscribed marks are 1, 2, 3, 4 or None.





NOTE: There are five vane plate lengths with the following rotor and cam ring marks:

3. Inspect flow control valve, as follows:





a. Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight.





b. Check the valve for leakage. Close one of the holes and apply 392 - 490 kPa (57 - 71 psi) of compressed air into the opposite side, and confirm that air does not come out from the end holes.





If necessary, replace the valve with one having the same letter as inscribed on the front housing.
Inscribed marks: A, B, C, D, E or F.





4. Inspect spring. Using calipers, measure the free length of the spring.
Minimum free length: 33.0 mm (1.299 inch).
If it is not within specification, replace the spring.
5. If necessary, replace oil seal, as follows:





a. Using Special Service Tool (SST) 09631 - 10030 or equivalent, tap out the oil seal from the front housing.

NOTICE: Be careful not to damage the bushing of the front housing.

b. Coat a new oil seal lip with power steering fluid.





c. Using a (24 mm) socket wrench, press in the oil seal.

NOTICE: Make sure to install the oil seal facing the correct direction.





6. If necessary, replace bearing, as follows:
a. Using a press, press out the bearing.
b. Using a snap ring expander, replace the snap ring with new one.

NOTICE: Be careful not to damage the shaft.

c. Coat a new bearing with power steering fluid.
d. Using a press, press in the bearing.

ASSEMBLY

NOTICE: When using a vise, do not overtighten it.

1. Coat with power steering fluid.





2. Install vane pump shaft with bearing, as follows:
a. Wind vinyl tape on the serrated part of the shaft.
b. Using Special Service Tool (SST) 09608 - 04031 or equivalent, press in the shaft with the bearing to the front housing.

NOTICE: Be careful not to damage the oil seal.

c. Using snap ring pliers, install a new snap ring to the front housing.
3. Install straight pins. Using a plastic hammer, drive in two new straight pins to the front housing.

NOTICE: Be careful not to damage the pins.





4. Install cam ring. Align the holes of the ring and straight pins, and install the cam ring with the inscribed mark facing outward.





5. Install vane pump rotor. Install the rotor with the inscribed mark facing outward.





6. Install ten vane plates. Install the vane plates with the round end facing outward.
7. Install new gasket. Install a new gasket to the front housing.
8. Install side plate. Align the holes of the plate and the straight pins.





9. Install wave washer. Install the wave washer so that its protrusions fit into the slots in the side plate.
10. Install rear housing, as follows:
a. Coat the two new O-rings with power steering fluid and install them to the housing.
b. Torque the two bolts.
Torque: 24 Nm (17 ft. lbs.).
11. Install spring, flow control valve and pressure port union, as follows:
a. Coat a new O-ring with power steering fluid and install it to the union.
b. Install the valve facing the correct direction.
c. Torque the union.
Torque: 83 Nm (61 ft. lbs.).
12. Install oil reservoir, as follows:
a. Coat a new O-ring with power steering fluid and install it to the reservoir.
b. Torque the three bolts.
Torque:
Front Side Bolt: 13 Nm (108 inch lbs.).
Rear Side Bolts: 24 Nm (17 ft. lbs.).





13. Install vane pump pulley. Using SST 09960 - 10010 (09962 - 01000, 09963 - 01000) or equivalents, to stop the pulley rotating, torque the nut.
Torque: 43 Nm (32 ft. lbs.).
14. Measure power steering vane pump rotating torque.