Exploded View

Replace the pump as an assembly if the parts indicated with asterisk (*) are worn or damaged.

Fig 1: Exploded View Of Pump Overhaul

G01955036

Special Tools Required

Attachment, 32 x 35 mm 07746-0010100
Driver 07749-0010000
Pulley holder 07ZAB-S5A0100

Disassembly

NOTE: Refer to Fig 1 as needed during the following procedure.

Remove the power steering pump (see Pump Replacement ).
Drain the fluid from the pump.
Hold the steering pump (A) with a vise with soft jaws, hold the pulley (B) with the special tool (C), and remove the pulley nut (D) and pulley. Be careful not to damage the pump housing with the jaws of the vise.

Fig 2: Removing Pulley Nut And Pulley
Remove the inlet joint and O-ring.
Remove the pressure control valve cap, O-ring, valve spring, and pressure control valve.
Remove the pump housing cap, O-ring, and pump preload spring.
Remove the pump cover, pump cover seal, and O-ring
Pull out the roll pin.
Remove the outer case, cam ring, rotor, vanes, and side plate.
Remove the rubber seal and slipper seal from the outer case.
Remove the O-rings from the bottom of the housing.
Remove the circlip, then remove the drive shaft by tapping the shaft end with the plastic hammer.
Remove the seal from the pump housing.
Inspection
Check the pressure control valve for wear, burrs, and other damage to the edges of the grooves in the valve.

Fig 3: Inspecting Pressure Control Valve
Inspect the bore of the pressure control valve on the pump housing for scratches and wear.
Slip the pressure control valve back in the pump housing, and check that it moves in and out smoothly. If OK, go to step 17; if not, replace the pump as an assembly. The pressure control valve is not available separately.

Fig 4: Slipping Pressure Control Valve Back In Pump Housing
Attach a hose (A) to the end of the pressure control valve (B) as shown in Fig 5 . Then submerge the pressure control valve in a container of power steering fluid or solvent (C), and blow in the hose.
- If air bubbles leak through the valve at less than 98 kPa (1.0 kgf/cm² , 14.2 psi), replace the pump as an assembly. The pressure control valve is not available separately.
- If the pressure control valve is OK, set it aside for reassembly later.
Fig 5: Attaching Hose To End Of Pressure Control Valve
Inspect the ball bearing by rotating the outer race slowly. If you feel any play (axial or radial) or roughness, remove the faulty ball bearing (A), and install a new one (B).

Fig 6: Inspecting Ball Bearing
Inspect each part shown with an asterisk in Fig 1 ; if any of them are worn or damaged, replace the pump as an assembly.
Reassembly
Install the new pump seal (A) (with its grooved side facing in) into the pump housing (B) by hand first, then drive it in using the special tools until the seal is fully seated in the pump housing.

Fig 7: Installing Pump Seal
Position the pump drive shaft (A) in the pump housing, then drive it in with the appropriate size socket wrench (B) as shown in Fig 8 .

Fig 8: Driving Pump Drive Shaft In With Size Socket Wrench
Install the 40 mm snap ring (C) with its radius side facing out.
Coat the new 23.8 mm O-ring (A) with power steering fluid, then position it into the groove on the bottom of the pump housing.

Fig 9: Installing O-Ring On Bottom of Pump Housing
Coat the new cover seal (A) and 13 mm O-ring (B) with the power steering fluid, then position them into the grooves on the cover (C).

Fig 10: Coating Cover Seal And O-Ring With Power Steering Fluid
Install the outer case (A) by aligning the slot (B) inside the outer case with the cover roll pin hole (C). Be sure that the slit (D) on the outer case faces the direction shown in Fig 11 .

Fig 11: Installing Outer Case Slit
Apply the power steering fluid to the rubber seal (E) black, and install it in the slot (F) of the outer case.
Apply power steering fluid to the slipper seal (G) (white), and install it on top of the rubber seal you just installed.
Align the slot (A) in the outer case with the roll pin hole (B) on the cover.

Fig 12: Aligning Slot In Outer Case With Roll Pin Hole
Install the cam ring (C) by aligning the slot (D) with the slot (A) in the outer case.
Insert the roll pin (E) into the slots between the cam ring and outer case, then push the roll pin into the set hole.
Install the rotor (A) in the cam ring (B).

Fig 13: Installing Rotor In Cam Ring
Set the 11 vanes (C) in the grooves in the rotor.
Make sure that the round ends (D) of the vanes are in contact with the sliding surface of the cam ring.
Place the side plate (A) on the cam ring with its"." mark (B) facing upward, and align the roll pin set hole (C) in the side plate with the roll pin end (D).

Fig 14: Placing Side Plate On Cam Ring With "." Facing Upward
Coat the new O-ring (E) with the power steering fluid, then position it into the groove on the side plate.
Install the pump housing (A) over the cover assembly (B).

Fig 15: Installing Pump Housing Over Cover Assembly
Align the bolt holes in the cover (B) with the threaded holes in the pump housing. Install the five flange bolts (C) loosely first, then torque the flange bolts in two or more steps with sequence shown in Fig 16 .

Fig 16: Tightening Bolts In Sequence
Push in the cam ring (A) from the pump housing cap hole (B) with a flat blade screwdriver, to make sure the cam ring is fully seated against the outer case.

Fig 17: Pushing In Cam Ring From Pump Housing Cap Hole With Screwdriver
Install the pump preload spring (A) in the pump housing.

Fig 18: Installing Pump Preload Spring In Pump Housing
Coat the new 12.7 mm O-ring (B) with power steering fluid, and install it on the pump housing cap (C).
Install the pump housing cap (C) on the pump housing, and tighten it to specified torque.
Coat the pressure control valve (A) with power steering fluid, and install pressure control valve and spring (B) on the pump housing.

Fig 19: Installing Pressure Control Valve And Spring
Coat the new 16.7 mm O-ring (C) with power steering fluid, and install it on the flow control valve cap (D).
Install the pressure control valve cap (D) on the pump housing, and tighten it to the specified torque.
Coat the new O-ring (A) with power steering fluid, and install it on the inlet joint (B).

Fig 20: Coating O-Ring With Power Steering Fluid
Install the inlet joint (B) on the pump housing.
Install the pulley (A), then loosely install the pulley nut (B). Hold the steering pump in a vise with soft jaws. Be careful not to damage the pump housing with the jaws of the vise.

Fig 21: Installing Pulley
Hold the pulley with the special tool, and tighten the pulley nut.
Check that the pump turns smoothly by turning the pulley. If it turns hard, loosen the five flange bolts on the cover, then retightening them try again in the same manner as in the step 36 .