Disassembly and Assembly

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:
Maximum: 0.3 Nm (2.4 inch lbs.) or less





2. Remove vane pump pulley.
Using Special Service Tool (SST) 09960 - 10010 (09962 - 01000, 09963 - 01000), to stop the pulley rotating, remove the nut.
3. Remove front and rear brackets.
Remove the 3 bolts and 2 nuts.
4. Remove suction port union.
a. Remove the bolt.
b. Remove the O-ring from the union.
5. Remove pressure port union, flow control valve and spring.
Remove the O-ring from the union.
6. Remove rear housing.
a. Remove the 4 bolts.
b. Remove the 2 O-rings from the housing.
7. Remove wave washer.
8. Remove side plate.
9. Remove gasket.
10. Remove cam ring, 10 vane plates and vane pump rotor. Using a screwdriver, remove the snap ring from the vane pump shaft.

NOTICE: Take care not to drop the plate.

11. Remove vane pump shaft.
12. Remove straight pins.
Remove the 2 pins from the front housing.

INSPECTION

CAUTION: When using a vise, do not overtighten it.





1. Check oil clearance between vane pump shaft and bushing.
Using a micrometer and a caliper gauge, measure the oil clearance.
Clearance:
- Standard: 0.03 - 0.05 mm (0.0012 - 0.0020 inch).
- Maximum: 0.07 mm (0.0028 inch).
If it is more than 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 Dimensions:
- Height: 8.6 mm (0.339 inch).
- Thickness: 1.397 mm (0.0550 inch).
- 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 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
There are 5 vane lengths with the following rotor and cam ring marks:

Rotor And Cam Ring Mark: - None
Vane Plate Part Number: 44345 - 26010
Vane Plate Length: 14.999 - 15.001 mm (0.59051 - 0.59059 inch).
Rotor And Cam Ring Mark: - 1
Vane Plate Part Number: 44345 - 26020
Vane Plate Length: 14.997 - 14.999 mm (0.59043 - 0.59051 inch).
Rotor And Cam Ring Mark: - 2
Vane Plate Part Number: 44345 - 26030
Vane Plate Length: 14.995 - 14.997 mm (0.59035 - 0.59043 inch).
Rotor And Cam Ring Mark: - 3
Vane Plate Part Number: 44345 - 26040
Vane Plate Length: 14.993 - 14.995 mm (0.59027 - 0.59035 inch).
Rotor And Cam Ring Mark: - 4
Vane Plate Part Number: 44345 - 26050
Vane Plate Length: 14.991 - 14.993 mm (O.59020 - 0.59027 inch).
3. Inspect flow control valve.





a. Coat the valve with power steering fluid and check that it falls smoothly into the valve hole of the front housing by its own weight.





b. Check the valve for leakage. Close one of the holes and apply 392 - 490 kPa (57 - 71 psi) of compressed air into the opposite side hole, and confirm that air does not come out from the end holes.





If necessary, replace the valve with the one having the same letter as inscribed on the front housing.
Inscribed Mark: A, B, C, D, E or F





4. Inspect spring.
Using 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 spring.
5. If necessary, replace oil seal.





a. Using a screwdriver with vinyl tape wound around its tip, remove the oil seal.

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 Special Service Tool (SST) 09950 - 60010 (09951 - 00240), 09950-70010 (09951 -07100), press in the oil seal.

NOTICE: Make sure to install the oil seal facing the correct direction.


REASSEMBLY

NOTICE: When using a vise, do not overtighten it.





1. Coat with power steering fluid.
2. Install vane pump shaft.
3. Install straight pins.
Using a plastic hammer, tap in 2 new pins.

CAUTION: Be careful not to damage the pins.





4. Install cam ring.
Align the holes of the ring and 2 straight pins, and install the ring with the inscribed mark facing outward.
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.
Install the 10 plates with the round end facing outward.
7. Install gasket.
Install a new gasket.
8. Install side plate.
Align the holes of the plate and 2 straight pins.





9. Install wave washer.
Install the washer so that its protrusions fit into the slots in the side plate.
10. Install rear housing.
a. Coat 2 new O-rings with power steering fluid and install them to the housing.
b. Torque the 4 bolts.
Torque 24 Nm (17 ft. lbs.).
11. 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 (62 ft. lbs.).
12. Install suction port union.
a. Coat a new O-ring with power steering fluid and install it to the union.
b. Torque the bolt.
Torque: 13 Nm (9 ft. lbs.).
13. Install front and rear brackets.
Torque the 3 bolts and 2 nuts.
Torque: 43 Nm (32 ft. lbs.).





14. Install vane pump pulley.
Using Special Service Tool (SST) 09960 - 10010 (09962 - 01000, 09963 - 01000) to stop the pulley rotating, torque the nut.
Torque: 43 Nm (32 ft. lbs.).
15. Measure PS vane pump rotating torque.