Disassembly and Assembly

DISASSEMBLY

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





1. Measure power steering vane pump rotating torque.
a. Check 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 equivalents, to stop the pulley rotating, remove the pulley set nut.
3. Remove suction port union.
a. Remove the two bolts.
b. Remove the O-ring from the union.
4. Remove pressure port union, flow control valve and spring.
Remove the O-ring from the union.





5. 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 of 6 mm (0.24 inch) and a pitch of 1.0 mm (0.039 inch).

c. Remove the O-ring from the seat.





6. Remove vane pump shaft with the bearing.
a. Using snap ring pliers, remove the snap ring from the front housing.
b. Temporarily install a appropriate plate washer and the pulley nut to the pump shaft.
c. Using SST 09910-00015 (09911-00011, 09912-00010) or equivalents, pull out the pump shaft with the bearing.
7. Remove rear bracket.
a. Remove the four bolts.
b. Remove the O-ring from the bracket.
8. Remove wave washer.
9. Remove side front plate, cam ring, vane pump rotor, 10 vane plates and side rear plate.





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

NOTICE: Take care not to drop the vane pump.

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

INSPECTION





1. Measure oil clearance between vane pump shaft and bushing. Using a micrometer and caliper gauge, measure the oil clearance.
Clearance:
Standard: 0.01 - 0.03 mm (0.0004 - 0.00012 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 vane plates.





a. Using a micrometer, measure the height, thickness and length of the 10 vane 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 vane plate.
Maximum clearance: 0.030 mm (0.0012 inch).
If it is more than maximum, replace the vane plate and/or rotor with one having the same mark stamped on the cam ring.





The Inscribed marks are 1, 2, 3, 4 or None.





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

3. Inspect flow control valve.





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: 36.9 mm (1.453 inch).
If it is not within specification, replace the spring.
5. If necessary, replace oil seal.





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 front housing.





b. Coat a new oil seal lip with power steering fluid.
c. Using a (22 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.
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 Special Service Tool (SST) 09238-47012 or equivalent, press in the shaft with the bearing to the front housing.
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 side front plate.





c. Using SST 09238-47012 or equivalent, press in the side front plate.

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


HINT: Align the wide hole on the side front plate with the longer straight pin.

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

NOTICE: Be careful not to damage the pin.





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





6. Install vane plates.
Install the 10 vane 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 side rear plate.
b. Align the wide hole with the longer straight pin and install the side rear plate.

NOTICE: Be careful not to damage the O-ring.





8. Install wave washer.
Install the wave 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 and install it to the rear bracket.
b. Torque the four 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. 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: 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. Torque the two bolts.
Torque: 13 Nm (9 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.