Disassembly and Assembly
DISASSEMBLY
NOTICE: When using a vise, do not overtighten it.
1. MEASURE POWER STEERING (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: 0.3 Nm (2.8 kgf-cm, 2.4 inch lbs.) or less
2. REMOVE VANE PUMP PULLEY
a. Using Special Service Tool (SST), stop the pulley rotating and loosen the nut.
b. Remove the nut and vane pump pulley from the vane pump shaft.
(SST) 09960-10010 (09962-01000, 09963-01000)
3. REMOVE FRONT AND REAR BRACKETS
Remove the 3 bolts, 2 nuts, front and rear brackets.
4. REMOVE SUCTION PORT UNION
a. Remove the bolt and suction port union.
b. Remove the O-ring from the suction port union.
5. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING
a. Remove the pressure port union, flow control valve and spring.
b. Remove the O-ring from the pressure port union.
6. REMOVE REAR HOUSING
a. Remove the 4 bolts and rear housing.
b. Remove the 2 O-rings from the rear housing.
7. REMOVE WAVE WASHER
8. REMOVE SIDE PLATE
9. REMOVE GASKET
10. REMOVE CAM RING, 10 VANE PLATES AND VANE PUMP ROTOR
a. Remove the cam ring and 10 vane plates.
NOTICE: Take care not to drop the plate.
b. Using a screwdriver, remove the snap ring and vane pump rotor from the vane pump shaft.
11. REMOVE VANE PUMP SHAFT
12. REMOVE 2 STRAIGHT PINS
Remove the 2 straight pins from the front housing.
INSPECTION:
NOTICE: When using a vise, do not overtighten it.
1. MEASURE OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING
Using a micrometer and caliper gauge, measure the oil clearance.
Standard clearance: 0.03 - 0.05 mm (0.0012 - 0.0020 inch)
Maximum clearance: 0.07 mm (0.0028 inch)
If it is more than the 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 vane plates.
Minimum height: 8.6 mm (0.339 inch)
Minimum thickness: 1.397 mm (0.05500 inch)
Minimum length: 14.991 mm (0.59016 inch)
b. Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane plate.
Maximum clearance: 0.035 mm (0.00138 inch)
If it is more than the maximum, replace the vane plate and/or vane pump rotor with the one having the same mark stamped on the cam ring.
Inscribed mark: 1, 2, 3, 4 or None
HINT: There are 5 vane plate lengths with the vane pump rotor and cam ring marks:
3. INSPECT FLOW CONTROL VALVE
a. Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight.
b. Check the flow control valve for leakage. Close one of the holes and apply 392 - 490 kPa (4 - 5 kgf/cm2, 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 flow control 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 vernier 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.
REPLACEMENT
NOTICE: When using a vise, do not overtighten it.
1. 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 front housing.
b. Coat a new oil seal lip with power steering fluid.
c. Using Special Service Tool (SST), press in the oil seal.
(SST) 09950-60010 (09951-00330), 09950-70010 (09951-07100)
NOTICE: Make sure to install the oil seal facing in the correct direction.
REASSEMBLY
NOTICE: When using a vise, do not overtighten it.
1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID
2. INSTALL 2 STRAIGHT PINS
Using a plastic hammer, tap in 2 new straight pins.
NOTICE: Be careful not to damage the straight pins.
3. INSTALL VANE PUMP SHAFT
4. INSTALL CAM RING
Align the holes of the cam ring and 2 straight pins, and install the cam ring with the inscribed mark facing outward.
5. INSTALL VANE PUMP ROTOR
a. Install the vane pump rotor with the inscribed mark facing outward.
b. Install a new snap ring to the vane pump shaft.
6. INSTALL 10 VANE PLATES
Install the 10 vane plates with the round end facing outward.
7. INSTALL GASKET Install a new gasket.
8. INSTALL SIDE PLATE Align the holes of the side plate and 2 straight pins, and install the side plate.
9. INSTALL WAVE WASHER
Install the wave 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 rear housing.
b. Install the rear housing with 4 bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)
11. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION
a. Install the spring.
b. Install the flow control valve facing in the correct direction.
c. Coat a new O-ring with power steering fluid and install it to the pressure port union.
d. Install the pressure port union.
Torque: 83 Nm (850 kgf-cm, 62 ft. lbs.)
12. INSTALL SUCTION PORT UNION
a. Coat a new O-ring with power steering fluid and install it to the suction port union.
b. Install the suction port union with bolt.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
13. INSTALL FRONT AND REAR BRACKETS
Install the front and rear brackets with 3 bolts and 2 nuts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
14. INSTALL VANE PUMP PULLEY
a. Install the vane pump pulley and nut to the vane pump shaft.
b. Using Special Service Tool (SST), stop the pulley rotating and torque the nut.
(SST) 09960-10010 (09962-01000, 09963-01000)
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
15. MEASURE POWER STEERING (PS) VANE PUMP ROTATING TORQUE