Disassembly and Assembly

POWER STEERING OIL PUMP


Disassembly and Assembly (Models with VK45DE)


COMPONENTS











INSPECTION BEFORE DISASSEMBLY
Disassemble oil pump only when the following malfunctions occur.
- If oil leakage is found on oil pump.
- Oil pump pulley is damaged or deformed.
- Performance of oil pump is low.

DISASSEMBLY

NOTE:
Secure oil pump in a vise if necessary.

CAUTION:
Use copper plates when securing in a vise.
1. Remove rear cover mounting bolts, and then remove rear cover from body assembly.
2. Remove gasket from body assembly.
3. Remove dowel pin, cartridge and side plate from body assembly.
4. Remove pulley mounting nut and washer, then remove pulley from drive shaft.





5. Remove snap ring from drive shaft and press out it.

CAUTION:
When removing snap ring, be careful not to damage drive shaft.





6. Remove oil seal from body assembly using a flat-bladed screwdriver.
7. Remove O-ring from body assembly.
8. Remove lock nut, and then remove copper washer, joint and Oring.
9. Remove connector bolt, and then remove O-ring, flow control valve and spring from body assembly
10. Remove mounting bolts of suction pipe, and then remove suction pipe from body assembly.
11. Remove O-ring from body assembly.

INSPECTION AFTER DISASSEMBLY

Body Assembly and Rear Cover Inspection
Check body assembly and rear cover for internal damage. Replace rear cover if it is damaged. Replace oil pump assembly if body assembly is damaged.

Cartridge Assembly Inspection
Check cam ring, rotor and vane for damage. Replace cartridge assembly if there are.

Side Plate Inspection
Check side plate for damage. Replace side plate if there are.

Flow Control Valve Inspection
Check flow control valve and spring for damage. Replace if there are.

ASSEMBLY

NOTE:
Secure oil pump in a vise if necessary.

CAUTION:
Use copper plates when securing in a vise.





1. Apply recommended grease to oil seal lips (1). Apply recommended fluid to around oil seal, and then install oil seal to body assembly.
2. Apply recommended fluid to drive shaft, and press drive shaft into body assembly, then install snap ring.
3. Apply recommended fluid to O-ring, and then install O-ring into body assembly.





4. Install side plate to body assembly.





5. Install dowel pin (3) into dowel pin hole (A), and then install cam ring (2) pointing it's D1 side toward the body assembly (1) side as shown in the figure.
- When installing cam ring, turn carved face with a letter E (B) of it to rear cover.

CAUTION:
Do not confuse the assembling direction of cam ring. If cam ring is installed facing the incorrect direction, it may cause oil pump operation malfunction.
6. Install rotor to body assembly.





- When installing rotor, turn mark face on rotor to body assembly.





7. Install vane to rotor so that arc of vane faces cam ring side.
8. Check if drive shaft turns smoothly.
9. Install gasket to body assembly.





10. Install rear cover to body assembly, and then tighten mounting bolts to the specified torque.
11. Install pulley and washer to drive shaft, and then tighten lock nut at the specified torque.
12. Apply recommended fluid to O-ring. Install spring, flow control valve and O-ring to body assembly, and then tighten connector bolt to the specified torque.
13. Apply recommended fluid to O-ring. Install O-ring, joint and copper washer to connector bolt, and then tighten lock nut to the specified torque.
14. Apply recommended fluid to O-ring, and then install O-ring to body assembly.
15. Install suction pipe to body assembly.