Disassembly and Assembly

DISASSEMBLY





NOTICE: Never remove the mounting bolts (partly resin coated) of the power steering ECU and motor. (The power steering ECU and motor should not be disassembly.)

1. REMOVE RESERVOIR CAP
2. REMOVE RESERVOIR
a. Loosen the clamp and remove the reservoir.
b. Remove the O-ring from the power steering vane pump housing.
3. REMOVE REAR HOUSING AND OIL STRAINER
a. Remove the 4 bolts, rear housing and oil strainer.
b. Remove the O-ring from the power steering vane pump housing.
4. REMOVE CAM RING, VANE PLATES, VANE PUMP ROTOR AND LOWER SIDE PLATE
a. Remove the cam ring, vane pump rotor and 10 vane plates.
b. Remove the lower side plate.

NOTICE: Take care not to drop the vane plate.





5. REMOVE FLOW CONTROL VALVE SPRING SEAT AND FLOW CONTROL VALVE
a. Using snap ring pliers, remove the snap ring.
b. Using a service bolt, pull it out together with the spring seat.





Recommended service bolt

c. Remove the O-ring from the spring seat.
d. Remove the flow control valve and spring.





6. REMOVE UPPER SIDE PLATE
a. Using a plastic-faced hammer, tap out the side plate and wave washer.
b. Remove the O-ring from the side plate.

INSPECTION
1. INSPECT VANE PUMP ROTOR AND VANE PLATES





a. Using a micrometer, measure the height, thickness and length of the 10 vane plates.
Minimum height: 5.4 mm (0.213 inch)
Minimum thickness: 0.882 mm (0.0347 inch)
Minimum length: 4.596 mm (0.1809 inch)





b. Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane plate.
Maximum clearance: 0.023 mm (0.0009 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: 0, 1, 2, 3, or 4





HINT: There are 5 vane plate heights corresponding to the following vane pump rotor and cam ring marks:

2. INSPECT FLOW CONTROL VALVE





a. Coat the flow control valve with power steering fluid and check that it falls smoothly into the valve hole of the rear housing by its own weight.





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





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





3. INSPECT SPRING
Using vernier calipers, measure the free length of the spring.
Minimum free length: 28.7 mm (1.130 inch)
If it is not within the specification, replace the spring.

REPLACEMENT
REPLACE UNION SEAT





a. Using a screw extractor, remove the union seat from the power steering vane pump housing.





b. Using a hammer arid an extension bar, lightly tap in a new union seat.

REASSEMBLY








1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID
2. INSTALL FLOW CONTROL VALVE AND FLOW CONTROL VALVE SPRING SEAT
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 spring seat.
d. Install the spring seat with the bolt hole facing outward to the rear housing.
e. Using snap ring pliers, install a new snap ring.





3. INSTALL LOWER SIDE PLATE
Align the holes of the side plate with the 2 straight pins, and install the lower side plate.

NOTICE: Make sure that the side plate is installed facing in the correct direction.





4. INSTALL CAM RING
Align the holes of the cam ring with the 2 straight pins, and install the cam ring with the inscribed mark facing upward.
5. INSTALL VANE PUMP ROTOR
Install the vane pump rotor with the inscribed mark facing upward.
6. INSTALL VANE PLATES
Install the 10 vane plates.





7. INSTALL UPPER SIDE PLATE
a. Coat a new O-ring with power steering fluid, and install it to the upper side plate.
b. Align the holes of the side plate with the 2 straight pins, and install the upper side plate.
8. INSTALL WAVE WASHER
Install the wave washer so that its protrusions fit into the slots in the upper side plate.





9. INSTALL OIL STRAINER AND REAR HOUSING
a. Coat a new O-ring with power steering fluid, and install it to the vane pump housing.
b. Install the oil strainer to the rear housing.
c. Align the O-ring with the oil hole of the rear housing.
d. Align the bolt set holes of the power steering vane pump housing with the bolt set holes of the rear housing, and install the rear housing with the 4 bolts.
Torque: 8.5 Nm (90 kgf-cm, 75 inch lbs.)





10. INSTALL RESERVOIR
a. Coat a new O-ring with power steering fluid, and install it to the power steering vane pump housing.
b. Install the reservoir with the clamp to the position shown in the illustration.
Torque: 7.0 Nm (70 kgf-cm, 61 inch lbs.)
11. INSTALL RESERVOIR CAP