Assembly

NOTE:
- Throughly clean all parts to be assembled.
- Before installing the parts, apply new fluid to all sliding and rotating surfaces.





1. Mount rear housing in a vise as shown in the illustration.





2. Install spool valve.
(a) Align the small hole of the spool sleeve with the hole of the rear housing, and insert the spool sleeve into the rear housing.





(b) Insert the compression spring and spool valve into the spool sleeve on the rear housing.
(c) Install the a new O-ring to the end plug.
(d) Apply fluid to the new O-ring.
(e) Temporarily install the end plug.





(f) Insert a 5 mm (0.19 inch) straight pin through the holes of the rear housing and spool sleeve.





(g) Using a 10 mm hexagon wrench, install the end plug and torque to 19 Nm (14 ft. lbs.).





(h) Pull out the straight pinch.





3. Remount rear housing in a vise as shown.
4. Install the casing.

NOTE: If rubber from the new O-rings adheres to the O-ring installation, replace the casing.

(a) Install a new O-ring to the rear housing groove.





(b) Align the pin hole of the casing with the straight pin on the rear housing, and install the casing.





5. Install rear thrust washer.
6. Install driven and drive rotors with the dot mark facing upward.





7. Install drive shaft.
8. Install front thrust washer.
9. Install front housing.
(a) Install a new O-ring to the casing groove.





(b) Align the pin holes of the front housing with the straight pin, and place the front housing on the casing
(c) Apply a light coat of fluid on the threads and under the heads of the bolts.
(d) Install the front housing with the 5 bolts and torque to 21 Nm (15 ft. lbs.).





10. Check drive shaft preload.
(a) Check that the drive shaft rotates smoothly without abnormal noise.
(b) Temporarily install the pulley nut, and check the rotating torque. The rotating torque is 0.3 Nm (2.6 inch lbs.).
11. Install pump pulley.
(a) Slide the pulley onto the drive shaft.





(b) Measure the clearance between the pulley end and drive shaft end. Standard clearance is 1.3 - 1.7 mm (0.051 - 0.067 inch) and the minimum clearance is 1.0 mm (0.039 inch). If the clearance is less than minimum, replace the pulley.
(c) Using SST 09960 - 10010, install the pulley with the nut.

NOTE: Tighten the nut by turning it counterclockwise and torque to 59 Nm (43 ft. lbs.)


12. Install solenoid valve
(a) Install a new O-ring to the solenoid valve.
(b) Install a new O-ring to the rear housing groove.
(c) Apply fluid to the two O-rings.
(d) Install the solenoid valve and torque to 39 Nm (28 ft. lbs.).
13. Install wire clamp.
(a) Install the wire clamp to the lead wire.
(b) Install the wire clamp to the rear housing.
14. Install suction port union.
(a) Install a new O-ring to the port union.
(b) Apply fluid to the new O-ring.
(c) Install the port union with the bolt and torque to 13 Nm (10 ft. lbs.).