Power Steering Pump Service
POWER STEERING PUMP, - RENEW (INCLUDES RESERVOIR / FILTER RENEW)
POWER STEERING PUMP, - REMOVE FOR ACCESS
POWER STEERING PUMP DRIVE DOG, - RENEW
POWER STEERING PUMP ADAPTOR, - RENEW
Disassemble
^ Place a suitable drain tin in position beneath the power steering pump (PAS), and release the PAS fluid reservoir hose securing clip. Disconnect the hose from the pump, and allow the fluid to drain. Fit plugs to the hose and the pump to prevent fluid loss and contamination.
^ Remove the power steering pump (PAS) securing bolts (1 Fig. 1), and dislocate the pump (2 Fig. 1)from its position.
^ Remove the drive coupling (3 Fig. 1) from either the pump drive dog or the auxiliary shaft drive dog.
Note: The next operation is only necessary during 'Remove for Access'.
^ The banjo hose nut can now be released, and the hose removed from the banjo (1 Fig. 2): allow the fluid to drain. Fit plugs to the hose and the banjo to prevent contamination.
This is the end of 'Remove for Access'
^ Note the position of the banjo (1 Fig. 2), and remove the banjo bolt (2 Fig. 2) and sealing washers (3 Fig. 2).
^ Pump Drive Dog. Holding the pump in a soft-jawed vice, fit puller legs (service tool JD 206/1) (1 Fig. 3) to the pump drive dog, (rotate the drive dog for access).
^ Pass the center bolt (service JD 206/3) (2 Fig. 3) fitted with tool nut (from service tool 18G 1445) (3 Fig. 3) through the hole of plate (from service tool JD 119) (4 Fig. 3), and lubricate the center bolt with oil.
^ Fit this assembly to the pump, engaging the puller legs in the plate cut-outs.
^ Engage the center bolt (2 Fig. 1) into the threads of the pump shaft,and hand tighten -then back-off 1/2 (one half) a turn - adjust the nut (3 Fig. 1) to remove free play at the puller legs.
^ Remove the pump / puller assembly from the vice, and clamp the plate (4 Fig. 1) in the vice as shown.
Caution: Assistance may he required to support the pump during the following operation.
^ Using one wrench to restrain the center bolt - ensure the puller legs are fully engaged under the drive dog -turn the tool nut with a second wrench to remove the drive dog from the pump shaft (Fig. 1).
^ Remove the center bolt, place the pump to one side, and remove the puller legs from the drive dog.
^ Unscrew the center bolt from the pump shaft and remove the pump.
^ Remove the pump drive dog,the puller legs and the center bolt from the plate. Remove the tool nut from the center bolt.
^ Pump Adaptor. Clamp the pump in a soft-jawed vice as shown in Fig. 2, remove the two adaptor to pump retaining bolts and remove the adaptor.
This is the end of 'Power Steering Pump - Renew' - Disassembly
Assembly
^ Pump Adaptor. Fit the new adaptor - ensure that the adaptor drain hole (1 Fig. 3) is in line with the pump outlet, ie, downwards when fitted to the engine - and secure with the two retaining bolts.
^ Pump Drive Dog. Secure the other end of the plate JD 119 (1 Fig. 4) in the vice, and fit the new drive dog (2 Fig. 3) to the pump shaft.
^ Place distance piece JD 206/2 (2 Fig. 4) onto the drive dog (ensure that the recess is towards the drive dog), and fit mandrel (3 Fig. 4) of service tool 18g 1445 onto the distance piece.
^ Lubricate the center bolt (4 Fig. 4) with oil and fit the bolt complete with tool nut (5 Fig. 4) through the mandrel, engage the center bolt into the threads of the pump shaft, and hand tighten - then back-off 1/2 (one half) a turn.
^ Hand tighten the tool nut (5 Fig. 4), and fit the pump / tool / assembly to the plate of tool JD 119(1 Fig. 4) (clamped in the vice).
^ Using one wrench to restrain the center bolt, turn the tool nut with a second wrench to press the drive dog onto the pump shaft.
^ Continue tightening the tool nut until resistance is felt-the recess in the distance piece will ensure correct positioning onto the pump shaft.
^ Remove the pump/tool assembly from the plate and then the tool assembly from the pump.
^ Ensure the mating surfaces are clean, grease a new coupling lightly refer to Specifications, Service Materials fit the new coupling to the pump drive dog and align the pump to the auxiliary drive shaft.
^ Refit the pump into position and secure with the three fixing bolts.
^ Refit the banjo to its original position, and secure with the banjo bolt and new sealing washers.
Note: The next operation is only necessary during 'Remove for Access'.
^ Remove the plugs from the banjo and the hose, reconnect the hose to the banjo, and secure with the clip.
Note: If the power steering pump is being replaced due to pump failure, then the reservoir / filter assembly must be renewed as follows.
^ Release the clip (1 Fig. 1) - reservoir to pump hose (already disconnected from the pump) - and remove the hose, fit plugs to the hose and the reservoir (3 Fig. 1) to prevent contamination.
^ Release the hose clip (2 Fig. 1) - reservoir to oil cooler hose, and remove the hose from the reservoir, fit plugs to the hose and the reservoir to prevent contamination.
^ Remove the reservoir (3 Fig. 1) from its retaining clamp (4 Fig. 1) and discard.
^ Fit the new reservoir to the clamp, and secure in position.
^ Remove the plugs from the hoses and pump, and any from the reservoir, connect the hoses and secure in position with the clips.
^ Fill and bleed the system.