Disassembly and Assembly

DISASSEMBLY OF POWER STEERING PUMP
1. MOUNT POWER STEERING PUMP IN VISE

NOTICE: Do not tighten the vise too tight.

2. REMOVE PS PUMP PULLEY
(a) Using SST, remove the pulley set nut.
SST 09616-30020 (For SV Series)
SST 09616-22010 (For VZV Series)

(b) Remove the pulley and woodruff key.

3. (Ex. SV Series for USA) REMOVE END PLATE

4. (SVS Series)
REMOVE AIR CONTROL VALVE
(a) Remove the air control valve.
(b) Remove the union seat.

5. REMOVE SUCTION PORT UNION
(a) Remove the bolt and union.
(b) Remove the 0-ring from the union.

6. REMOVE FLOW CONTROL VALVE
(a) Remove the pressure port union.
(b) Remove the 0-ring from the union.

7. REMOVE FLOW CONTROL SPRING SEAT
(a) Using snap ring pliers, remove the snap ring.

(b) Temporarily install a bolt to the seat and pull out the seat.
(c) Remove the 0-ring from the seat.

8. REMOVE REAR HOUSING
(a) Using two screwdrivers, remove the snap ring.

(b) Using a plastic hammer, tap Out the rear housing and wave washer.
(c) Remove the 0-ring from the rear housing.

9. REMOVE REAR SIDE PLATE
(a) Using a plastic hammer, tap the shaft end and remove the rear plate.
(b) Remove the 0-ring from the rear plate.

10. REMOVE PUMP SHAFT, CAM RING AND VANE PLATES
(a) Remove the pump shaft with cam ring, vane plates from the front housing.
(b) Remove the cam ring and ten vane plates from the pump shaft.
(c) Remove the long straight pin from the front housing.

11. REMOVE ROTOR AND FRONT PLATE
(a) Using a screwdriver, remove the snap ring.
(b) Remove the rotor and front plate from the pump shaft.
(c) Remove the two 0-rings from the front plate.

(d) Using a pin punch and hammer, drive out the straight pin.

INSPECTION OF POWER STEERING PUMP
1. MEASURE OIL CLEARANCE OF SHAFT AND BUSHING
Using a micrometer and calipers, measure the oil clearance.
Standard clearance: 0.01 -0.03 mm (0.0004 - 0.0012 in.)
Maximum clearance: 0.07 mm (0.0028 in.)

If more than maximum, replace the entire power steering pump.

2. INSPECT ROTOR AND VANE PLATES
(a) Using a micrometer, measure the height, thickness and length of the vane plates.
Minimum height: 8.0 mm (0.315 in.)
Minimum thickness: 1.77 mm (0.0697 in.)
Minimum length: 14.97 mm (0.5894 in.)

(b) Using a feeler gauge, measure the clearance between the rotor groove and vane plate.
Maximum clearance: 0.03 mm (0.0012 in.)

If more than maximum, replace the vane plate and/or rotor with one having the same mark stamped on the cam ring.
Inscribed mark: 1,2,3,4 or None

HINT: There are five vane lengths with the following rotor and cam ring marks, refer to image.

3. INSPECT FLOW CONTROL VALVE
(a) Coat the valve with power steering fluid and check that it fails smoothly into the valve hole by its own weight.

(b) Check the flow control valve for leakage.
Close one of the holes and apply compressed air [4 - 5 kg/cm2 (57 - 71 psi, 392 490 kpa)] into the opposite side, and confirm that air does not come out from the end holes.

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

4. INSPECT FLOW CONTROL SPRING
Using a scale, measure the free length of the spring.
Spring length: 36 - 38 mm (1.42-1.49 in.)

If not within specification, replace the spring.

5. IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver, pry out the oil seal.

(b) Using a socket wrench and hammer, drive in a new oil seal.

ASSEMBLY OF POWER STEERING PUMP
1. COAT ALL SLIDING SURFACES WITH POWER
STEERING FLUID BEFORE ASSEMBLY

2. INSTALL FRONT PLATE AND ROTOR TO PUMP SHAFT
(a) Using a plastic hammer, drive the short straight pin to the front plate.

(b) Install two new 0-rings to the front plate.
(c) Install the front plate to the pump shaft.

(d) Install the rotor to the pump shaft.
(e) Install the snap ring.

3. INSTALL PS PUMP SHAFT TO FRONT HOUSING
(a) Coat the oil seal lip with MP grease.
(b) Install the long straight pin to the front housing.

(c) Align the hole of the front plate and straight pin and tap in the pump shaft with a plastic hammer.

NOTICE: Be careful not to damage the oil seal and 0-rings.

4. INSTALL CAM RING
Align the holes of the cam ring and straight pins, and insert the cam ring with the inscribed mark facing outward.

5, INSTALL VANE PLATES
Install the vane plates with the round end facing outward.

6. INSTALL REAR SIDE PLATE AND 0-RING
(a) Install a new 0-ring to the side plate.
(b) Align the holes of the side plate with the pins, and install the plate.

7. INSTALL REAR HOUSING
(a) Install the wave washer.

(b) Install a new 0-ring to the rear housing.
(c) Using a plastic hammer, tap in the rear housing.
(d) Install the snap ring.

5. MEASURE PUMP SHAFT PRELOAD
(a) Check that the shaft rotates smoothly without abnormal noise.
(b) Temporarily install the pulley nut and check the rotating torque.
Rotating torque: 2.8 kg-cm(2.4 in.-lb, 0.3 N.m) or less

9. INSTALL FLOW CONTROL SPRING SEAT
(a) Install a new 0-ring in the spring seat.
(b) Insert the spring seat with the bolt hole facing Outward to the housing.

10. INSTALL SPRING, FLOW CONTROL VALVE, 0-RING AND PRESSURE PORT UNION
(a) Install the spring and the valve into the housing.
(b) Install a new 0-ring in the groove of the pressure port union.

11. INSTALL SUCTION PORT UNION
(a) Install a new 0-ring to the suction port union.
(b) Install the suction port union into the housing.
(c) Install and torque the bolt.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)

12. (SVS Series)
INSTALL AIR CONTROL VALVE

13. INSTALL PS PUMP PULLEY
(a) Install the woodruff key to the shaft.
(b) Install the pulley and nut to the shaft.
(c) Using SST, torque the nut.
SST 09616-30020 (For SV Series)
SST 09616-22010 (For VZV Series)

Torque: 440 kg-cm (32 ft-lb, 43 N.m)

14. (Ex. SV Series for USA) INSTALL END PLATE
Torque: 130 kg-cm (9 ft-lb, 13 N.m)