Disassembly and Assembly
DISASSEMBLY
NOTICE: When using a vise, do not overtighten it.
1. MEASURE PS VANE PUMP ROTATING 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
Using SST, stop the pulley rotating and remove the pulley set nut.
SST 09960-10010 (09962-01000, 09963-01000)
3. REMOVE OIL RESERVOIR
a. Remove the 3 bolts and oil reservoir.
b. Remove the O-ring from the oil reservoir.
4. 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.
5. REMOVE REAR HOUSING
a. Remove the 2 bolts and rear housing.
b. Remove the 2 O-rings from the rear housing.
6. REMOVE WAVE WASHER
7. REMOVE SIDE PLATE
8. REMOVE CAM RING, 10 VANE PLATES AND VANE PUMP ROTOR
NOTICE: Be careful not to drop the vane plate.
9. REMOVE 2 STRAIGHT PINS
Remove the 2 straight pins from the front housing.
10. REMOVE GASKET
11. REMOVE VANE PUMP SHAFT WITH BEARING
a. Using snap ring pliers, remove the snap ring from the front housing.
b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the vane pump shaft.
c. Press out the vane pump shaft with the bearing.
NOTICE: Be careful not to damage the oil seal lip.
INSPECTION
NOTICE: When using a vise, do not overtighten it.
1. CHECK 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 vane pump shaft and front housing.
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 vane pump rotor groove and vane plate.
Maximum clearance: 0.033 mm (0.0013 inch)
If it is more than the maximum, replace the vane plate and/or vane pump 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 plate 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 flow control valve for leakage. Close one of the holes and apply compressed air 392- 490 kPa (4 - 5 kgf/cm2, 57 - 71 psi) into the opposite side, and confirm that air does not come out from the end holes.
If necessary, replace the flow control valve with 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: 33.2 mm (1.307 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 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 SST, press in the oil seal.
SST 09950-60010 (09951-00330), 09950-70010 (09951-07100)
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
2. IF NECESSARY, REPLACE BEARING
a. Press out the bearing from the vane pump shaft.
b. Using 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. Press in the bearing to the shaft.
REASSEMBLY
NOTICE: When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID
2. INSTALL VANE PUMP SHAFT WITH BEARING
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the vane pump shaft.
b. Using SST, press in the vane pump shaft with the bearing.
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 2 STRAIGHT PINS
Using a plastic hammer, tap in 2 new straight pins to the front housing.
NOTICE: Be careful not to damage the straight pins.
4. INSTALL CAM RING
Install the cam ring with the inscribed mark facing outward.
HINT: Align the holes of the cam ring with the 2 straight pins.
5. INSTALL VANE PUMP ROTOR
6. INSTALL 10 VANE PLATES AND GASKET
a. Install the 10 vane plates with the round end facing outward.
b. Install a new gasket on the front housing.
NOTICE: Be careful the direction of the gasket.
7. INSTALL SIDE PLATE
Align the holes of the side plate and 2 straight pins.
8. INSTALL WAVE WASHER
Install the wave washer so that its protrusions fit into the slots in the side plate.
9. INSTALL REAR HOUSING
a. Coat 2 new O-rings with power steering fluid and install them to the rear housing.
b. Install the rear housing with the 2 bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)
10. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION
a. Install the spring.
b. Install the flow control valve facing in the correct direction.
c. Coat a new O-ring with power steering fluid, and install it to the pressure port union. Install the pressure port union.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)
11. INSTALL OIL RESERVOIR
a. Coat a new O-ring with power steering fluid and install it to the oil reservoir.
b. Install the oil reservoir with 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.)
12. INSTALL VANE PUMP PULLEY
a. Install the vane pump pulley and nut to the vane pump shaft. Using SST, stop the pulley rotating and torque the pulley set nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
13. MEASURE PS VANE PUMP ROTATING TORQUE