Assembly

ASSEMBLY
1) Reassembly precautions
(1) Whenever 0-rings, oil seals, and snap rings are removed, they must be replaced with new ones.
(2) Thoroughly wash parts and allow to dry. They must be kept free from cleaning oil and dust.
(3) Reassembly procedure must be performed in clean place. Ensure that parts are kept away from waste threads or other dust particles.
(4) Cleaning oil lends to stay inside the front casing. Remove it completely by blowing compressed air.
(5) Ensure that parts are tree from rust. (Use specified hydraulic oil for rust prevention after cleaning and drying.)
(6) Reverse the sequence of disassembly procedures.





2) Shaft
(1) Apply grease to oil seal and inner surface of front casing (at bearing location).

CAUTION: Make sure that the front body internal surfaces are free from damage.

(2) Using ST, press-fit oil seal into front body. ST 340099AA000 INSTALLER

CAUTION: When press-fitting, use care to prevent damage to surface mating with rear body.

NOTE: Orient oil seal toward correct direction.





(3) Using ST, press-fit shaft assembly into front body and mount snap ring. ST 340099AA020 INSTALLER

NOTE: Turn snap ring to ensure that it fits right into the groove.





3) Cartridge assembly
(1) Apply specified hydraulic oil to 0-rings and fit them into front casing.
(2) Install side plate to front casing.

CAUTION: Use care not to let side plate gall.





(3) Mount rotor onto shaft.
(4) Install 10 vanes into rotor with their nose radius facing toward cam ring.
(5) Install cam ring to front casing, securing with knock pins.

CAUTION: Do not use hammer to fit knock pins in position.





4) Rear cover
(1) Mount seal washer on front casing.
(2) With knock pin positions aligned, install rear cover.

Tightening torque:
16 ± 2 Nm (1.6 ± 0.2 kg-m, 11.6 ± 1.4 ft-Ib.)

CAUTION: Loosely tighten bolts in the sequence (1), (3), (2), and (4) shown in figure. Then, tighten in the same sequence.





5) Spool Valve
(1) Install spring into front casing. Then, with spool valve dipped in specified hydraulic oil, install it into the front casing.
(2) Using a 5-mm dia. round bar, ensure that valve moves smoothly.
(3) Set O-ring, with grease applied to it, onto connector and secure connector to front casing.

Tightening torque:
74 ± 5 Nm (7.5 ± 0.5 kg-m, 54.2 ± 3.6 ft-lb)

CAUTION:
- Use care to prevent damage to 0-ring at installation.
- When tightening connector, ensure that 0-ring does not protrude or get caught.

6) Check
(1) When reassembly procedures have been completed, turn shaft by hand to ensure it turns smoothly. If it binds or other unusual conditions are evident, disassemble again and check for foreign matter trapped on sliding surfaces and improper installation. Eliminate the cause of trouble.
(2) Check followings by referring to "CHECK" article.
- Excessive play in pulley shaft
- Ditch deflection of pulley
- Resistance to rotation of pulley
- Measurement of generated oil pressure