Power Steering Pump: Service and Repair

VANE PUMP

COMPONENTS:

REMOVAL
1. REMOVE FRONT WHEEL RH
2. DRAIN POWER STEERING FLUID
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE FAN AND GENERATOR V BELT

5. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
a. Remove the clip and disconnect the No. 1 oil reservoir to pump hose.

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

6. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
a. Remove the bolt and disconnect the pressure feed tube from the pump bracket rear.
b. Using a 27 mm wrench to hold the pressure port union, remove the union bolt and gasket.

7. REMOVE VANE PUMP ASSEMBLY
a. Disconnect the connector from the oil pressure switch.
b. Using SST and a 14 mm deep socket, loosen the 2 bolts.
SST 09249-63010
c. Remove the vane pump.

DISASSEMBLY

NOTICE: Do not overtighten when using a vise.

1. FIX VANE PUMP ASSEMBLY
a. Using SST, hold the vane pump in a vise.
SST 09630-00014 (09631-00132)
2. REMOVE REAR VANE PUMP BRACKET
a. Remove the bolt and vane pump bracket.
3. REMOVE POWER STEERING SUCTION PORT UNION
a. Remove the bolt and suction port union.
b. Remove the O-ring from the suction port union.

4. 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 compression spring.
5. REMOVE POWER STEERING OIL PRESSURE SWITCH

NOTICE: If the oil pressure switch is dropped or damaged, replace it with a new one.

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

7. REMOVE SHAFT SUB-ASSEMBLY WITH PULLEY
a. Using 2 screwdrivers, remove the snap ring from the shaft.
b. Remove the shaft with pulley.
8. REMOVE VANE PUMP ROTOR
a. Remove the 10 vane pump plates.
b. Remove the vane pump rotor.
9. REMOVE VANE PUMP CAM RING
10. REMOVE FRONT VANE PUMP SIDE PLATE

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

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

11. REMOVE VANE PUMP HOUSING OIL SEAL
a. Using a screwdriver, remove the oil seal.

NOTICE: Be careful not to damage the front housing.

INSPECTION

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

a. Using a micrometer, measure the thickness of the vane pump plates.
Standard 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.
3. 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 it lacks smoothness, replace the vane pump assembly.

b. Check the flow control valve for leakage. Close one of the holes and apply compressed air, 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 air leaks, replace the vane pump assembly.

4. INSPECT FLOW CONTROL VALVE COMPRESSION SPRING
a. Using a vernier caliper, measure the free length of the compression spring.
Minimum free length: 36.9 mm (1.453 inch)
If the length is less than the minimum, replace the vane pump assembly.
5. 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.

REASSEMBLY

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

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

NOTICE: Make sure that the oil seal is installed in the correct direction as shown in the illustration.

2. INSTALL SHAFT SUB-ASSEMBLY WITH PULLEY
a. Coat the bush surface of the front housing with power steering fluid.
b. Gradually insert the shaft with shaft from the pulley side.

NOTICE: Do not damage the oil seal lip in the front housing.

3. INSTALL FRONT VANE PUMP SIDE PLATE

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

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

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

NOTICE: Make sure that the front side plate is installed in the correct direction as shown in the illustration.

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

NOTICE: Make sure that the cam ring is installed in the correct direction.

5. INSTALL VANE PUMP ROTOR

a. Coat the vane pump rotor with power steering fluid.
b. Install the vane pump rotor.

NOTICE: Vane pump rotor has no specific direction.

c. Coat all 10 vane pump plates with power steering fluid.
d. Install the vane pump plates with the round end facing outward.

6. INSTALL VANE PUMP SHAFT SNAP RING
a. Using a screwdriver and snap ring expander, install a new snap ring to the shaft.

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

8. 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 pulley rotating torque.
Standard rotating torque: 0.27 Nm (2.8 kgf-cm, 2.4 ft. lbs.) or less
If rotating torque is not as specified, check the installation condition of each part.
9. INSTALL POWER STEERING OIL PRESSURE SWITCH
a. Install the oil pressure switch onto the vane pump assembly.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

10. INSTALL FLOW CONTROL VALVE
a. Coat the compression spring and flow control valve with power steering fluid.
b. Install the compression spring and flow control valve.
c. Coat a new O-ring with power steering fluid and install it onto the pressure port union.
d. Install the pressure port union.
Torque: 69 Nm (704 kgf-cm, 51 ft. lbs.)

11. INSTALL REAR VANE PUMP BRACKET
a. Install the rear vane pump bracket with the bolt.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)

HINT: Make sure that the stopper of the bracket touches the vane pump body, and then torque the bolt.

12. INSTALL POWER STEERING SUCTION PORT UNION
a. Coat a new O-ring with power steering fluid, and install it to the suction port union.
b. Install the suction port union with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)

INSTALLATION

1. INSTALL VANE PUMP ASSEMBLY
a. Temporarily install the 2 bolts to the vane pump.
b. Install the vane pump with the 2 bolts.
c. Using SST and a 14 mm deep socket, fully tighten the bolts.
SST 09249-63010
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).

This torque valve is effective when SST is parallel to the torque wrench.

d. Connect the connector to the oil pressure switch.

2. CONNECT PRESSURE FEED TUBE ASSEMBLY
a. Install the pressure feed tube and a new gasket to the vane pump with the union bolt.

HINT: Make sure the stopper of the pressure feed tube touches the vane pump body.

b. Using a 27 mm wrench to hold the pressure port union, torque the union bolt.

Torque: 52 Nm (525 kgf-cm, 38 ft. lbs.)
c. Install the pressure feed tube with the bolt to the pump bracket rear.

Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)

3. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
a. Connect the No. 1 oil reservoir to pump hose with the clip.

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

4. INSTALL FAN AND GENERATOR V BELT
5. INSTALL FRONT FENDER APRON SEAL RH
6. INSTALL FRONT WHEEL RH
7. BLEED POWER STEERING FLUID
8. CHECK FOR FLUID LEAKS