Disassembly and Assembly

DISASSEMBLY

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





1. REMOVE VANE PUMP PULLEY
Using SST to stop the pulley rotating, remove the pulley set nut.
SST 09960-10010 (09962-01000, 09963-01000)





2. MEASURE PS VANE PUMP ROTATING TORQUE
a. Check that the pump rotates smoothly without abnormal noise.
b. Temporarily install the pulley set nut, and using a torque wrench, check the pump rotating torque.
Rotating torque: 0.25 Nm (2.5 kgf-cm, 2.2 inch lbs.) or less
3. REMOVE OIL RESERVOIR
a. Remove the 3 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 2 bolts.
6. REMOVE CAM RING, VANE PUMP ROTOR AND 10 VANE PLATES

NOTICE: Take care not to drop the plates.

7. REMOVE 2 STRAIGHT PINS
8. REMOVE GASKET





9. REMOVE VANE PUMP SHAFT WITH BEARING
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 WAVE WASHER
a. Using a plastic hammer, tap out the plate and wave washer.
b. Remove the 2 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.
Standard clearance: 0.03 - 0.05 mm (0.0012 - 0.0020 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: 8.6 mm (0.339 inch)
Minimum thickness: 1.40 mm (0.0551 inch)
Minimum length: 14.99 mm (0.5902 inch)





b. Using a feeler gauge, measure the clearance between the rotor groove and vane plate.
Maximum clearance: 0.04 mm (0.0016 inch)
If it is more than the maximum, replace the vane plate and/or 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 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 (4 - 5 kgf/cm2, 57 - 71 psi) of compressed air into the opposite side hole, and confirm that air does not come out from the end holes.





If necessary, replace the 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 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





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

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 socket wrench (24 mm), 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 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.


REASSEMBLY

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

1. COAT WITH POWER STEERING FLUID
2. INSTALL VANE PUMP SHAFT WITH BEARING
a. Wind vinyl tape on the serrated part of the shaft.





b. Using SST, press in the shaft with the bearing to the front housing.
SST 09608-04031

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 2 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 ring with the inscribed mark facing outward.





5. INSTALL VANE PUMP ROTOR
Install the rotor with the inscribed mark facing outward.





6. INSTALL 10 VANE PLATES
Install the vane plates with the round end facing outward.
7. INSTALL GASKET
Install a new gasket to the front housing.
8. INSTALL SIDE PLATE
Align the holes of the plate and 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
a. Coat 2 new O-rings with power steering fluid and install them to the housing.
b. Torque the 2 bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)
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: 83 Nm (850 kgf-cm, 61 ft. lbs.)
12. INSTALL OIL RESERVOIR
a. Coat a new O-ring with power steering fluid and install it to the reservoir.
b. Torque the 3 bolts.
Torque:
Front side bolt: 13 Nm (130 kgf-cm, 9 ft. lbs.)
Rear side bolts: 24 Nm (240 kgf-cm, 17 ft. lbs.)





13. INSTALL VANE PUMP PULLEY
Using SST to stop the pulley rotating, torque the pulley set nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
14. MEASURE PS VANE PUMP ROTATING TORQUE
Using a spanner (24 mm) to hold the pressure port union, torque the union bolt with a new gasket.

HINT: Make sure that the stopper of the tube touches the pump housing as shown in the illustration, then torque the union bolt.

Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
15. CONNECT RETURN HOSE
Install the clip.