Power Steering Pump: Service and Repair

OVERHAUL

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

1. REMOVE FRONT WHEEL RH
2. DRAIN POWER STEERING FLUID
3. REMOVE FRONT FENDER LINER RH
4. REMOVE FRONT FENDER APRON SEAL RH
5. SEPARATE OIL RESERVOIR TO PUMP HOSE NO.1
a. Remove the clip and disconnect the oil reservoir to pump hose No. 1.

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

6. REMOVE POWER STEERING OIL PRESSURE SWITCH
a. Disconnect the connector.
b. Remove the oil pressure switch from the union bolt.

NOTICE: Be careful not to drop the oil pressure switch.

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





7. SEPARATE PRESSURE FEED TUBE ASSY
a. Using a spanner (22 mm) to hold the pressure port union, remove the union bolt and gasket.





8. REMOVE VANE PUMP V BELT
a. Loosen the 2 bolts and remove the vane pump V belt.
9. REMOVE VANE PUMP ASSY
a. Remove the 2 bolts and vane pump assembly.
10. REMOVE POWER STEERING SUCTION PORT UNION
a. Remove the bolt and suction port union.
b. Remove the O-ring from the suction port union.





11. REMOVE VANE PUMP PULLEY
a. Using SST, stop the pulley rotation and loosen the nut.
SST 09960-10010 (09962-01000, 09963-01000)
b. Remove the nut and vane pump pulley from the vane pump shaft.
12. REMOVE PRESSURE PORT UNION
a. Remove the pressure port union.
b. Remove the O-ring from the pressure port union.
13. REMOVE FLOW CONTROL VALVE
14. REMOVE FLOW CONTROL VALVE COMPRESSION SPRING
15. REMOVE PUMP BRACKET FRONT
a. Remove the 3 bolts, pump bracket front and pump bracket rear from the vane pump assembly.
16. REMOVE VANE PUMP HOUSING REAR
a. Remove the 4 bolts and pump housing rear from the pump housing front.
b. Remove the gasket.
c. Remove the 2 O-rings from the pump housing rear.
17. REMOVE VANE PUMP SIDE PLATE REAR
a. Remove the wave washer from the side plate rear.
b. Remove the side plate rear.
18. REMOVE VANE PUMP CAM RING





19. REMOVE VANE PUMP ROTOR
a. Remove the 10 vane plates from the vane pump rotor.
b. Using a screwdriver, remove the shaft snap ring from the vane pump shaft.
c. Remove the vane pump rotor.
20. REMOVE VANE PUMP SHAFT





21. REMOVE VANE PUMP HOUSING OIL SEAL
a. Using a screwdriver with vinyl tape wound around its tip, remove the oil seal.

NOTICE: Be careful not to damage the pump housing.





22. INSPECT OIL CLEARANCE
a. Using a micrometer and a 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 assembly.
23. INSPECT VANE PUMP ROTOR AND VANE PLATES





a. Using a micrometer, measure the height, thickness and length of the vane 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 vane pump rotor groove and vane plate.
Maximum clearance: 0.035 mm (0.0014 inch)
If it is more than the maximum, replace the vane pump assembly.
24. 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 by its own weight.





b. Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392 - 490 kPa (4 - 5 kgf/cm2, 57 - 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.





25. INSPECT FLOW CONTROL VALVE COMPRESSION SPRING
a. Using vernier calipers, measure the free length of the spring.
Minimum free length: 32.3 mm (1.272 inch)
If it is not within the specification, replace the vane pump assembly.
26. INSPECT PRESSURE PORT UNION
If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage, replace the vane pump assembly.





27. INSTALL VANE PUMP HOUSING OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST and a press, install a new 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.





28. INSTALL VANE PUMP SHAFT
a. Coat inside bushing surface of the pump housing front with power steering fluid.
b. Gradually insert the vane pump shaft from the pulley side.

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





29. INSTALL VANE PUMP ROTOR
a. Install the vane pump rotor.
b. Using a snap ring expander, install a new snap ring to the vane pump shaft.
30. INSTALL VANE PUMP CAM RING





a. Align the holes of the cam ring with 2 straight pins, and install the cam ring with inscribed mark facing outward.





b. Coat 10 vane plates with power steering fluid.
c. Install the vane plates with the round end facing outward.
d. Install a new gasket.
31. INSTALL VANE PUMP SIDE PLATE REAR
a. Coat a new O-ring with power steering fluid and install it to the side plate rear.
b. Align the groove of the cam ring with that of the side plate, install the side plate rear.





c. Install the wave washer so that its protrusions fit into the slots in the side plate rear.
32. INSTALL VANE PUMP HOUSING REAR
a. Coat a new O-ring with power steering fluid and install it to the pump housing rear.
b. Install the pump housing rear with the 4 bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)





33. MEASURE PS VANE PUMP ROTATION TORQUE
a. Check that the pump rotates smoothly without abnormal noise.
b. Temporarily install the pulley set nut.
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
34. INSTALL PUMP BRACKET FRONT
a. Install the front and rear brackets with the 3 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
35. INSTALL FLOW CONTROL VALVE COMPRESSION SPRING
a. Coat the compression spring with power steering fluid and install it.
36. INSTALL FLOW CONTROL VALVE
a. Coat the flow control valve with power steering fluid.
b. Install the flow control valve.
37. INSTALL PRESSURE PORT UNION
a. Coat a new O-ring with power steering fluid and install it to the pressure port union.
b. Install the pressure port union.
Torque: 83 Nm (850 kgf-cm, 62 ft. lbs.)





38. INSTALL VANE PUMP PULLEY
a. Install the pulley to the vane pump shaft.
b. Using SST, stop the pulley rotation and torque the nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
39. 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: 13 Nm (130 kgf-cm, 9 ft. lbs.)





40. INSTALL VANE PUMP ASSY
a. Temporarily install the vane pump assembly with the 2 (A and B) bolts.
41. INSTALL VANE PUMP V BELT
a. Install the vane pump V belt and adjust the V belt tension.
b. Torque the bolt A.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
c. Torque the bolt B.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)





42. CONNECT PRESSURE FEED TUBE ASSY
a. Using a spanner (22 mm) to hold the pressure port union, connect the pressure feed tube assembly with the union bolt and a new gasket.
Torque: 51 Nm (525 kgf-cm, 38 ft. lbs.)

HINT: Make sure the stopper of the pressure feed tube touches the front bracket as shown in the illustration, then install the union bolt.

43. INSTALL POWER STEERING OIL PRESSURE SWITCH
a. Install the oil pressure switch to the union bolt.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)

NOTICE: Be careful not to prevent oil from being attached to the connector.

b. Connect the connector.
44. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
a. Connect the oil reservoir to pump hose No. 1.
b. Install the clip.
45. INSTALL FRONT FENDER APRON SEAL RH
46. INSTALL FRONT FENDER LINER RH
47. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
48. BLEED POWER STEERING FLUID
49. INSPECT FLUID LEAK