Disassembly and Assembly

DISASSEMBLY

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





1. Measure PS vane pump rotation torque.
a. Check that the pump rotates smoothly without abnormal noise.
b. Using a torque wrench, check the pump rotating torque.
Rotating torque: 0.25 Nm (2.2 inch lbs.) or less.





2. Remove vane pump pulley.
Using Special Service Tool (SST) 09960 - 10010 (09962 - 01000, 09963 - 01000) or equivalent, to stop the pulley rotating, remove the pulley set nut.
3. Remove air control valve.
4. Remove suction port union.
a. Remove the 2 bolts.
b. Remove the O-ring from the union.
5. Remove pressure port union, flow control valve and spring.
Remove the O-ring from the union.





6. Remove spring seat.
a. Using snap ring pliers, remove the snap ring from the front housing.
b. Temporarily install a bolt to the seat and pull it out together with the seat.

HINT: Use a bolt with diameter 6 mm (0.24 inch) and pitch 1.0 mm (0.039 inch).

c. Remove the O-ring from the seat.





7. Remove vane pump shaft with bearing.
a. Using snap ring pliers, remove the snap ring from the front housing.
b. Temporarily install a appropriate plate washer and the pulley set nut to the pump shaft.
c. Using SST 09910 - 00015 (09911 - 00011, 09912 - 00010), pull out the pump shaft with the bearing.
8. Remove rear bracket.
a. Remove the 4 bolts.
b. Remove the O-ring from the rear bracket.
9. Remove wave washer.





10. Remove side front plate, cam ring, vane pump rotor, vane plates and side rear plate.
a. Using an extension bar and press, press out the side front plate, cam ring, rotor, vane plates and side rear plate as an assembly.
b. Remove the O-ring from the side rear plate.
c. Remove the cam ring, rotor and the 10 vane plates.

NOTICE: Take care not to drop the vane plate.

d. Remove the shorter straight pin from the side front plate.
e. Remove the 2 O-rings from the side front plate.
f. Using pliers, remove the longer straight pin from the front housing.

INSPECTION

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





1. Measure oil clearance between vane pump shaft and bushing.
Using a micrometer and caliper gauge, measure the oil clearance.
Standard clearance: 0.030 - 0.045 mm (0.0012 - 0.0018 inch)
Minimum clearance: 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 vane plates.
a. Using a micrometer, measure the height, thickness and length of the 10 plates.
Minimum:
Height: 8.0 mm (0.315 inch)
Thickness: 1.77 mm (0.0697 inch)
Length: 14.97 mm (0.5894 inch)





b. Using a feeler gauge, measure the clearance between the rotor groove and plate.
Maximum clearance: 0.035 mm (0.0014 inch)





c. If it is more than maximum, replace the plate and/or rotor with one having the same mark stamped on the cam ring. Inscribed mark: 1, 2, 3, 4 or None.





HINT: There are 5 vane lengths with the following rotor and cam ring marks:





3. Inspect flow control valve.
a. Coat the flow control 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.





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





4. Inspect spring.
Using calipers, measure the free length of the spring.
Minimum free length: 36.0 mm (1.42 inch).
If it is not within the specification, replace the spring.





5. If necessary, replace oil seal.
a. Using SST 09631 - 10030, tap out the oil seal.

NOTICE: Be careful not to damage the front housing.

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





c. Using SST 09950-60010 (09951-00300), 09O50-70010 (09951-07100) and a press, press in the oil seal.

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





6. If necessary, replace bearing.
a. Using a snap ring expander, remove the snap ring from the vane pump shaft.

NOTICE: Be careful not to damage the shaft.

b. Using a press, press out the bearing.





c. Coat a new bearing with power steering fluid.
d. Using a press, press in the bearing.
e. Using a snap ring expander, install a new snap ring.

NOTICE: Be careful not to damage the shaft.





7. If necessary, replace union seat.
a. Using a screw extractor, remove the union seat.





b. Using an extension bar and hammer, tap in a new union seat.

NOTICE: Before installing the union seat, remove dust sticking to the front housing.

REASSEMBLY

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

1. Coat with power steering fluid.
2. Install vane pump shaft with bearing.





a. Using SST 09238 - 47012, press in the pump shaft with the bearing.
b. Using snap ring pliers, install a new snap ring to the front housing.
3. Install side front plate.
a. Install a new longer straight pin to the front housing.

NOTICE: Be careful not to damage the pin.

b. Coat 2 new O-rings with power steering fluid and install them to the plate.





c. Using SST 09238 - 47012, press in the plate.

NOTICE:
- Make sure you install the side front plate facing the correct direction.
- Be careful not to damage the O-ring.

HINT: Align the wide hole of the plate and longer straight pin.

d. Install a new shorter straight pin to the plate.

NOTICE: Be careful not to damage the pin.





4. Install cam ring.
Align the wide hole of the ring and longer straight pin, and install the ring with the inscribed mark facing outward.
5. Install the vane pump rotor with the inscribed mark facing outward.





6. Install vane plates.
Install the 10 plates with the round end facing outward.





7. Install side rear plate.
a. Coat a new O-ring with power steering fluid and install it to the plate.
b. Using a press, press in the plate.

NOTICE: Be careful not to damage the O-ring.
HINT: Align the wide hole of the plate and longer straight pin.





8. Install wave washer.
Install the washer so that its protrusions fit into the slots in the side rear plate.
9. Install rear bracket.
a. Coat a new O-ring with power steering fluid an install it to the bracket.
b. Install the bracket to the front housing.
c. Torque the 4 bolts.
Torque: 39 Nm (29 ft. lbs.).
10. Install spring seat.
a. Coat a new O-ring with power steering fluid and install it to the spring seat.
b. Install the spring seat with the bolt hole facing outward.
c. Using snap ring pliers, install a new snap ring.
11. Install spring, flow control valve and pressure port union.
a. Install the valve facing the correct direction.
b. Coat a new O-ring with power steering fluid and install it to the union.
c. Torque the union.
Torque: 69 Nm (51 ft. lbs.)
12. Install suction port union.
a. Coat a new O-ring with power steering fluid and install it to the union.
b. Install the union to the vane pump assembly.
c. Torque the 2 bolts.
Torque: 13 Nm (9 ft. lbs.)
13. Install air control valve.
Torque the valve.
Torque: 36 Nm (27 ft. lbs.).
14. Install vane pump pulley.
Using SST 09960-10010 (09962-01000) to stop the pulley rotating, torque the pulley set nut.
Torque: 43 Nm (32 ft. lbs.)
15. Measure PS vane pump rotating torque.