Disassembly and Reassembly

Part 1 Of 2:

Part 2 Of 2:

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 to stop the pulley rotating, 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
Remove the O-ring from the union.
5. REMOVE REAR HOUSING
a. Remove the 2 bolts and rear housing.
b. Remove the 2 O-rings from the housing.
6. REMOVE WAVE WASHER
7. REMOVE SIDE PLATE
8. REMOVE CAM RING, VANE PLATES AND VANE PUMP ROTOR
a. Remove the 10 plates.

NOTICE: Take care not to drop the plate.

b. Using a screwdriver, remove the snap ring from the vane pump shaft.
9. REMOVE STRAIGHT PINS
Remove the 2 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. Wind vinyl tape on the serrated part of the vane pump shaft.
c. Press out the 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 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 plates.
Minimum height: 8.6 mm (0.339 inch)
Minimum thickness: 1.397 mm (0.0550 inch)
Minimum length: 14.991 mm (0.5902 inch)





b. Using a feeler gauge, measure the clearance between the rotor groove and plate.
Maximum clearance: 0.035 mm (0.0014 inch)





If it is more than the maximum, replace the plate and/or 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 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 valve.

NOTICE: Install a new valve with the same inscribed mark as the old one.

Inscribed mark: A, B, C, D, E or F





4. INSPECT SPRING
Using calipers, measure the free length of the spring.
Minimum free length: 33.2 mm (1.307 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. 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 WITH POWER STEERING FLUID





2. INSTALL VANE PUMP SHAFT WITH BEARING
a. Wind vinyl tape on the serrated part of the vane pump shaft.
b. Using SST, press in the 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 STRAIGHT PINS
Using a plastic hammer, tap in 2 new pins to the front housing.

NOTICE: Be careful not to damage the pins.





4. INSTALL CAM RING
Install the ring with the inscribed mark facing outward.

HINT: Align the holes of the cam ring with the straight pins.

5. INSTALL VANE PUMP ROTOR
a. Install the rotor with the inscribed mark facing outward.
b. Install a new snap ring to the vane pump shaft.





6. INSTALL VANE PLATES AND GASKET
a. Install the 10 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 plate and 2 straight pins.





8. INSTALL WAVE WASHER
Install the 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 housing.
b. Torque 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 valve facing the correct direction.
b. Coat a new O-ring with power steering fluid and install it to the union.
c. Torque the 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
Using SST to stop the pulley rotating, torque the nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
13. MEASURE PS VANE PUMP ROTATING TORQUE