Overhaul
DisassemblyCAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly.
NOTE:
- Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a solvent.
- Always replace the O-rings and rubber seals with new ones before assembly.
- Apply recommended power steering fluid to the parts indicated in the assembly procedures.
- Do not allow dust, dirt, or other foreign materials to enter the power steering system.
- Replace the pump as an assembly if the parts indicated with asterisk (*) are worn or damaged.
1. Drain the fluid from the pump.
2. Hold the steering pump in a vise with soft jaws, hold the pulley with the special tool, and remove the pulley nut and pulley.
CAUTION: Be careful not to damage the pump housing with the jaws of the vise and extension bar.
3. Loosen the flow control valve cap with a hex wrench and remove it.
4. Remove the O-ring, flow control valve and spring.
5. Remove the inlet joint and O-ring.
6. Remove the pump cover and pump cover seal.
7. Remove the outer side plate, pump cam ring, pump rotor, pump vanes, side plate and O-rings.
8. Remove the snap ring, then remove the sub-valve from the pump housing.
9. Remove the circlip, then remove the pump drive shaft by tapping the shaft end with the plastic hammer.
10. Remove the pump seal spacer and pump seal.
Inspection
Flow Control Valve:
1. Check the flow control valve for wear, burrs, and other damage to the edges of the grooves in the valve.
2. Inspect the bore the flow control valve for scratches or wear.
3. Slip the valve back in the pump, and check that it moves in and out smoothly.
If OK, go on step 4; if not, replace the pump as an assembly. The flow control valve is not available separately.
4. Attach a hose to the end of the valve as shown.
5. Submerge the valve in a container of power steering fluid or solvent, and blow in the hose. If air bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm2, 14.2 psi), repair it as follows.
6. Hold the bottom end of the valve with an open end wrench.
7. Unscrew the seat in the top end of the valve, and remove any shims, the relief check ball, relief valve and relief valve spring.
8. Clean all the parts in solvent, dry them off, then reassemble and retest the valve. If the flow control valve tests OK, reinstall it in the pump. If the flow control valve still leaks air, replace the pump as an assembly. The flow control valve is not available separately.
NOTE: If necessary, relief pressure is adjusted at the factory by adding shims under the check ball seat. If you found shims in your valve, be sure you reinstall as many as you took out.
Ball Bearing:
1. Inspect the ball bearing by rotating the outer race slowly. If any play or roughness is felt, replace the ball bearing.
2. Remove and discard the ball bearing using a press as shown.
3. Install the new ball bearing using a press as shown.
Ball Bearing Replacement:
Reassembly
1. Align the pin of the sub-valve with the oil passage in pump housing, and push down the sub-valve. Install the snap ring properly.
2. Install the new pump seal in the pump housing by hand, then install the pump seal spacer.
NOTE: Insert the pump seal with its grooved side facing in.
3. Position the pump drive shaft in the pump housing, then drive it in using a special tool as shown.
4. Install the 40 mm circlip with its radiused side facing out.
5. Coat the pump cover seal and the cover bushing with the power steering fluid, then install the pump cover seal into the groove in the pump cover.
6. Install the outer side plate over the two rollers.
7. Set the pump cam ring over the two rollers with the " - " mark on the cam ring upward.
8. Assemble pump rotor to the pump cover with the " - " marks on the rotor facing down.
9. Set the 10 vanes in the grooves in the rotor.
NOTE: Be sure that the round ends of the vanes are in contact with the sliding surface of the cam ring.
10. Coat the O-ring with power steering fluid, and install it into the grooves in the side plate.
11. Install the side plate on the cam ring by aligning the roller set holes in the side plate with the rollers.
12. Coat the O-ring with power steering fluid, and position it into the pump housing.
13. Install the pump cover assembly in the pump housing.
14. Coat the flow control valve with power steering fluid.
15. Install the flow control valve and spring on the pump housing.
16. Coat the O-ring with power steering fluid, and install it on the flow control valve cap.
17. Install the flow control valve cap on the pump housing and tighten it.
18. Coat the O-ring with power steering fluid, and install it into the grooves in the inlet joint.
19. Install the inlet joint on the pump housing.
20. Install the pulley as shown below, then loosely install the pulley nut. Hold the steering pump in a vise with soft jaws.
CAUTION: Be careful not to damage the pump housing with the jaws of the vise.
21. Hold the pulley with the special tool, and tighten the pulley nut.
22. Check that the pump turns smoothly by turning the pulley by hand.