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 (2.5 kgf-cm, 2.2 inch lbs.) or less





2. REMOVE VANE PUMP PULLEY
a. Using SST, stop the pulley rotating and loosen the nut.
SST 09960-10010 (09962-01000, 09963-01000)
b. Remove the nut and vane pump pulley from the vane pump shaft.
3. REMOVE AIR CONTROL VALVE
4. REMOVE SUCTION PORT UNION
a. Remove the 2 bolts and suction port union.
b. Remove the O-ring from the suction port union.
5. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING
a. Remove the pressure port union, flow control valve and spring.
b. Remove the O-ring from the pressure port 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 spring seat and pull it out together with the spring 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 spring 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 vane pump shaft.
c. Using SST, pull out the vane pump shaft with the bearing.
SST 09910-00015 (09911-00011, 09912-00010)
8. REMOVE REAR BRACKET
a. Remove the 4 bolts and rear bracket.
b. Remove the O-ring from the rear bracket.





9. REMOVE WAVE WASHER
10. REMOVE SIDE FRONT PLATE, CAM RING, VANE PUMP ROTOR, 10 VANE PLATES AND SIDE REAR PLATE
a. Using an extension bar, press out the side front plate, cam ring, vane pump rotor, 10 vane plates and side rear plate as an assembly.
b. Remove the O-ring from the side rear plate.
c. Remove the cam ring, vane pump 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)
Maximum clearance: 0.07 mm (0.0028 inch)
If it is more than the 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)
Minimum thickness: 1.77 mm (0.0697 inch)
Minimum length: 14.97 mm (0.5894 inch)





b. Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane plate.
Maximum clearance: 0.030 mm (0.0012 inch)





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





HINT: There are 5 vane plate lengths corresponding to the vane pump 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 of the front housing by its own weight.





b. Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392 - 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi) into the opposite side hole, and confirm that air does not come out from the end holes.





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





4. INSPECT SPRING
Using vernier calipers, measure the free length of the spring.
Minimum free length: 36.0 mm (1.417 inch)
If it is not within the specification, replace the spring.

REPLACEMENT

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

1. IF NECESSARY, REPLACE OIL SEAL





a. Using SST, tap out the oil seal.
SST 09631-10030

NOTICE: Be careful not to damage the front housing.





b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-00010 (09951-00180, 09951-00300, 09952-06010), 09950-70010 (09951-07100)

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

2. 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. Press out the bearing.
c. Coat a new bearing with power steering fluid.





d. Press in the bearing.
e. Using a snap ring expander, install a new snap ring.

NOTICE: Be careful not to damage the shaft.

3. 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 PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID. Refer to Diagrams; Exploded View
2. INSTALL VANE PUMP SHAFT WITH BEARING
a. Using SST, press in the vane pump shaft with the bearing.
SST 09238-47012
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, press in the side front plate.
SST 09238-07012

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

HINT: Align the wide hole of the side front plate and longer straight pin. Install a new shorter straight pin to the side front plate.

NOTICE: Be careful not to damage the pin.





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





6. INSTALL 10 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. Press in the side rear plate.

NOTICE: Be careful not to damage the ring.

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





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. Install the rear bracket with the 4 bolts.
Torque: 39 Nm (400 kgf-cm, 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 spring.
b. Install the flow control valve facing in the correct direction. Refer to Diagrams; Exploded Views.
c. Coat a new O-ring with power steering fluid and install it to the pressure port union.
d. Install the pressure port union.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
12. INSTALL SUCTION PORT UNION
a. Coat a new O-ring power steering fluid and install it to the suction port union.
b. Install the suction port union with the 2 bolts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
13. INSTALL AIR CONTROL VALVE
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





14. INSTALL VANE PUMP PULLEY
a. Install the nut and vane pump pulley to the vane pump shaft.
b. Using SST, stop the pulley rotating and torque the nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
15. MEASURE PS VANE PUMP ROTATING TORQUE