Power Steering Pump: Service and Repair

VANE PUMP ASSEMBLY
OVERHAUL

NOTICE:
^ Do not overtighten when using a vise.
^ When installing, coat the parts indicated by arrows with power steering fluid.

1. REMOVE FR WIPER ARM LH
2. REMOVE FR WIPER ARM RH
3. REMOVE HOOD TO COWL TOP SEAL
4. REMOVE COWL TOP VENTILATOR LOUVER LH
5. REMOVE COWL TOP VENTILATOR LOUVER RH
6. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
7. REMOVE COWL PANEL SUB-ASSEMBLY
8. REMOVE VANE PUMP OIL RESERVOIR COVER
9. DRAIN POWER STEERING FLUID
10. REMOVE FRONT WHEEL RH
11. REMOVE ENGINE UNDER COVER RH





12. SEPARATE PRESSURE FEED TUBE ASSEMBLY
a. Using SST, disconnect the pressure feed tube assembly from the vane pump assembly.
SST 09023-12701
b. Remove the clip and disconnect the return hose.

NOTICE: Take care not to spill fluid on the V belt.

c. Disconnect the oil pressure sensor connector.
13. REMOVE VANE PUMP STAY REAR
a. Remove the bolt, the stay rear and the heat insulator.





14. REMOVE VANE PUMP ASSEMBLY
a. Remove bolts B and C and the adjusting strut.
b. Loosen bolt A sufficiently so that the vane pump assembly can be removed.

HINT: Bolt A cannot be removed.





15. FIX VANE PUMP ASSEMBLY
a. Using SST, secure the vane pump assembly in a vise.
SST 09630-00014 (09631-00132)
16. REMOVE VANE PUMP OIL RESERVOIR CAP SUB-ASSEMBLY
17. REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY
a. Remove the 3 bolts and the oil reservoir assembly.
b. Remove the O-ring from the oil reservoir assembly.
18. REMOVE PUMP BRACKET FRONT
a. Remove the 2 bolts, the bracket front and the bracket rear.





19. REMOVE FLOW CONTROL VALVE
a. Remove the pressure port union.
b. Remove the O-ring from the pressure port union.
c. Remove the flow control valve and the compression spring.
20. REMOVE POWER STEERING OIL PRESSURE SENSOR
a. Remove the oil pressure sensor from the housing front.





21. REMOVE VANE PUMP HOUSING REAR
a. Remove the 4 bolts and the housing rear from the housing front.
b. Remove the O-ring from the housing rear.





22. REMOVE W/PULLEY SHAFT SUB-ASSEMBLY
a. Using 2 screwdrivers, remove the snap ring from the w/ pulley shaft sub-assembly.
b. Remove the w/pulley shaft sub-assembly.
23. REMOVE VANE PUMP ROTOR
a. Remove the 10 vane pump plates.
b. Remove the vane pump rotor.
24. REMOVE VANE PUMP CAM RING
25. REMOVE VANE PUMP SIDE PLATE FRONT





a. Remove the side plate front from the housing front.
b. Remove the O-ring from the side plate front.





c. Remove the O-ring from the housing front.





26. REMOVE VANE PUMP HOUSING OIL SEAL
a. Using a screwdriver and shop rag, remove the housing oil seal.

NOTICE: Be careful not to damage the housing front.





27. INSPECT VANE PUMP SHAFT AND BUSH IN HOUSING FRONT
a. Using a micrometer and a caliper gauge, measure the oil clearance.
Maximum clearance: 0.07 mm (0.0028 inch) or less
If the clearance exceeds the maximum, replace the vane pump assembly.
28. INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES





a. Using a micrometer, measure the thickness of the vane pump plates.
Minimum thickness: 1.405 to 1.411 mm (0.05531 to 0.05555 inch)





b. Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and the vane plates.
Maximum clearance: 0.03 mm (0.0012 inch)
If the clearance exceeds the maximum, replace the vane pump assembly.





29. INSPECT FLOW CONTROL VALVE
a. Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole under its own weight.
If necessary, replace the vane pump assembly.





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





30. INSPECT FLOW CONTROL VALVE COMPRESSION SPRING
a. Using vernier calipers, measure the free length of the compression spring.
Minimum free length: 29.2 mm (1.150 inch)
If it is less than minimum, replace the vane pump assembly.
31. INSPECT PRESSURE PORT UNION
If the union seat in the pressure port union is severely damaged, it may cause fluid leakage. In that case, replace the vane pump assembly.





32. INSTALL VANE PUMP HOUSING OIL SEAL
a. Coat a new housing oil seal lip with power steering fluid.
b. Using SST and a press, install a new housing oil seal.
SST 09950-60010 (09951-00280), 09950-70010 (09951-07100)

NOTICE: Make sure that the oil seal is installed correctly.





33. INSTALL W/PULLEY SHAFT SUB-ASSEMBLY
a. Coat inside bushing surface of the housing front with power steering fluid.
b. Gradually insert the w/pulley shaft sub-assembly.

NOTICE: Be careful not to damage the oil seal lip.

HINT: Wrap the shaft with vinyl tape before inserting.

34. INSTALL VANE PUMP SIDE PLATE FRONT





a. Coat a new O-ring with power steering fluid and install it to the housing front.





b. Coat a new O-ring with power steering fluid and install it to the side plate front.





c. Align the dent of the side plate front with that of the housing front to install.

NOTICE: Make sure that the side plate front is installed correctly.





35. INSTALL VANE PUMP CAM RING
a. Align the dent of the cam ring with that of the side plate front, and install the cam ring with the inscribed mark facing upward.
36. INSTALL VANE PUMP ROTOR





a. Install the vane pump rotor.





b. Apply power steering fluid to 10 vane pump plates.
c. Install the vane pump plates with the round end facing outward.





37. INSTALL VANE PUMP SHAFT SNAP RING
a. Using a screwdriver and a snap ring expander, install a new snap ring to the w/pulley shaft sub-assembly.





38. INSTALL VANE PUMP HOUSING REAR
a. Apply power steering fluid to a new O-ring and install it to the housing rear.
b. Align the straight pin of the housing rear with the dents of the cam ring, the side plate front and the housing front, and install the housing rear with the 4 bolts.
Torque: 22 Nm (224 kgf-cm, 16 ft. lbs.)





39. INSPECT PRELOAD
a. Check that the pump rotates smoothly without abnormal noise.
b. Temporarily install the service bolt.
Recommended service bolt:
Thread diameter: 10 mm (0.39 inch)
Thread pitch: 1.25 mm (0.0492 inch)
Bolt length: 50 mm (1.97 inch)
c. Using a torque wrench, check the pump rotating torque.
Rotating torque: 0.27 Nm (2.8 kgf-cm. 2.4 inch lbs.) or less
If the rotating torque is not as specified, check installation of the housing oil seal.
40. INSTALL POWER STEERING OIL PRESSURE SENSOR
a. Apply power steering fluid to a new O-ring and install it to the oil pressure sensor.
b. Install the oil pressure sensor to the housing front.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)





41. INSTALL FLOW CONTROL VALVE
a. Apply power steering fluid to the compression spring and the flow control valve.
b. Install the compression spring and the flow control valve.
c. Apply power steering fluid to a new O-ring and install it to the pressure port union.
d. Install the pressure port union.
Torque: 69 Nm (704 kgf-cm, 51 ft. lbs.)
42. INSTALL PUMP BRACKET FRONT
a. Install the bracket front and the bracket rear with the 2 bolts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
43. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY
a. Apply power steering fluid to a new O-ring and install it to the oil reservoir assembly.
b. Install the oil reservoir assembly with the 3 bolts to the housing front.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
44. INSTALL VANE PUMP OIL RESERVOIR CAP SUB-ASSEMBLY





45. INSTALL VANE PUMP ASSEMBLY
a. Temporarily install the vane pump assembly with bolt A.

HINT: After adjusting the V belt tension, torque the bolt.

b. Install the adjusting strut with bolt B.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
c. Temporarily install bolt C.

HINT: After adjusting the V belt tension, torque the bolt.

46. INSTALL VANE PUMP STAY REAR





a. Install the stay rear, to the housing rear, as shown in the illustration.





b. Install the heat insulator and the stay rear with the bolt.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

NOTICE: Install the heat insulator by pressing its projection into a hole in the bracket rear, as shown in the illustration.

47. CONNECT PRESSURE FEED TUBE ASSEMBLY





a. Using SST, connect the pressure feed tube assembly.
SST 09023-12701
Torque: 41 Nm (414 kgf-cm, 30 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
^ This torque value is effective when SST(s) is parallel to a torque wrench.





b. Check that the pressure feed tube assembly is properly installed to the stay rear.
c. Connect the return hose with the clip.

NOTICE: Take care not to spill fluid on the V belt.

d. Connect the oil pressure sensor connector.
48. ADJUST VANE PUMP V BELT
49. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
50. ADD POWER STEERING FLUID
51. BLEED POWER STEERING FLUID
52. INSPECT FLUID LEAK
53. INSTALL ENGINE UNDER COVER RH
54. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
55. CHECK POWER STEERING FLUID LEVEL IN RESERVER
56. INSTALL VANE PUMP OIL RESERVOIR COVER
57. INSTALL COWL PANEL SUB-ASSEMBLY
58. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
59. INSTALL COWL TOP VENTILATOR LOUVER LH
60. INSTALL COWL TOP VENTILATOR LOUVER RH
61. INSTALL HOOD TO COWL TOP SEAL
62. INSTALL FR WIPER ARM LH
63. INSTALL FR WIPER ARM RH