Page 1177 of 2890
B4M0671A
7) Connect pipes A and B to four pipe joints of gearbox.
Connect upper pipe A first, and lower pipe B second.
Tightening torque:
13±3 N⋅m (1.3±0.3 kg-m, 9.4±2.2 ft-lb)
8) Install jack-up plate.
9) Connect battery negative terminal.
10) Feed the specified fluid and discharge air.
NOTE:
Never start the engine before feeding the fluid; otherwise
vane pump might be seized up.
B4M0674A
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Page 1178 of 2890

B4M0558
9. Oil Pump (Power Steering System)
A: REMOVAL
1) Remove ground cable from battery.
2) Drain the working fluid about 0.35(0.4 US qt, 0.3 Imp
qt) from oil tank.
3) Remove pulley belt cover bracket.
B4M0559A
4) Loosen oil pump pulley nut, then remove bolts which
secure alternator.
5) Loosen pulley belt(s).
6) Remove the nut and detach oil pump pulley.
B4M0556A
7) Remove bolt A. Disconnect pipe C from oil pump. Dis-
connect pipe D from oil tank.
CAUTION:
Do not allow fluid from the hose end to come into
contact with pulley belt.
To prevent foreign matter from entering the hose
and pipe, cover the open ends of them with a clean
cloth.
Except when only oil tank needs to be inspected,
detach oil tank and oil pump as a unit. Then separate
one from the other on a work bench to prevent oil from
spilling on any part of the engine.
B4M0560
8) Remove three bolts from the front side of oil pump and
detach the pump.
9) Remove three bolts from the lower side of bracket and
detach the bracket.
CAUTION:
The bracket does not need to be removed unless it is
damaged.
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9. Oil Pump (Power Steering System)
Page 1179 of 2890

B4M0561A
10) Place oil pump in a vise, remove two bolts from oil tank
and detach oil tank.
CAUTION:
Do not place oil pump directly in the vise; use soft
pads and hold oil pump lightly to protect the pump.
B: CHECK
In accordance with the following table, check all removed
parts for wear and damage, and make repair or replace-
ment if necessary.
No. Parts Inspection Corrective action
1 Oil pump (Exterior)(1) Crack, damage or oil leakage Replace oil pump with a new one.
(2) Play of pulley shaftMeasure radial play and axial play.
If any of these exceeds the service limit,
replace oil pump with a new one.
4-3 [W9B1].>
2 Pulley(1) Damage Replace it with a new one.
(2) BendMeasure V ditch deflection.
If it exceeds the service limit, replace
pulley with a new one.
[W9B1].>
3 Cap Crack or damage Replace it with a new one.
4 Strainer(1) Clogging with dirt Wash it.
(2) Breakage Replace it with a new one.
5 Oil pump (Interior)(1) Defect or burning of vane pumpCheck resistance to rotation of pulley.
If it is past the service limit, replace oil
pump with a new one.
[W9B1].>
(2) Bend in the shaft or damage to
bearingOil pump emits a noise that is markedly
different in tone and loudness from a
sound of a new oil pump when turning with
a string put around its pulley, replace oil
pump with a new one.
6 O-ring Crack or deterioration Replace it with a new one.
7 Oil tank Crack, damage or oil leakage Replace it with a new one.
8 Bracket Crack or damage Replace it with a new one.
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9. Oil Pump (Power Steering System)
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G4M0172
1. SERVICE LIMIT
Make a measurement as follows. If it exceeds the specified
service limit, replace the parts with new ones.
CAUTION:
Fix oil pump on a vise to make a measurement. At
this time, hold oil pump with the least possible force
between two wood pieces.
Do not set outside of flow control valve or pulley on
a vise; otherwise outside or pulley might be deformed.
Select properly sized wood pieces.
G4M0173
Play of pulley shaft
Service limit:
Radial play (Direction
)
0.4 mm (0.016 in) or less
Axial play (Direction
)
0.9 mm (0.035 in) or less
On condition:
P: 9.8 N (1.0 kg, 2.2 lb)
G4M0174
Ditch deflection of pulley
Service limit:
1.0 mm (0.039 in) or less
NOTE:
Read the value for one surface of V ditch, and then the
value for another off the dial.
G4M0175
Resistance to rotation of pulley
Service limit:
Maximum load; 9.22 N (0.94 kg, 2.07 lb) or less
NOTE:
A rather higher value may be indicated when pulley
starts turning.
Measure the load during rotation and make a judgment.
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9. Oil Pump (Power Steering System)
Page 1181 of 2890
C: DISASSEMBLY
B4M0142A
1Pulley
2Snap ring
3Bearing
4Oil seal
5Shaft
6Connector
7O-ring
8Spool valve
9Spring
10Front casing
11Rear cover
12Knock pin
13Seal washer
14Cam ring
15Vane
16Rotor
17Side plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 16±2 (1.6±0.2, 11.6±1.4)
T2: 61±7 (6.2±0.7, 45.0±5.2)
T3: 74±5 (7.5±0.5, 54.2±3.6)
B4M0561A
1) Oil pump body
(1) Place oil pump in a vise, and remove two bolts
which secure tank.
CAUTION:
Do not place oil pump directly in vise; use soft pads
and hold oil pump lightly to protect it.
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4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)
Page 1182 of 2890
G4M0178
(2) Remove four bolts which secure rear cover.
G4M0923
(3) Remove the following parts from front casing.
1Seal washer
2Knock pin ...............................................................2 ea.
3Cam ring
4Rotor
5Vane .....................................................................10 ea.
6Side plate
7O-ring .....................................................................2 ea.
CAUTION:
Discard old seal washer; replace with a new one.
G4M0180
2) Control valve
Slightly loosen outlet connector, and remove connector.
Remove the following parts for pump casing.
Spool valve assembly
Flow control spring
Connector
O-ring
G4M0181
3) Shaft
(1) Remove snap ring from front casing.
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9. Oil Pump (Power Steering System)
Page 1183 of 2890

G4M0182
(2) Remove shaft using a hand press.
CAUTION:
Discard old drive shaft assembly; replace with a new
one.
Be careful not to scratch or dent casing’s surface
which serves as a seal.
G4M0183
(3) Pry oil seal off using a screwdriver.
CAUTION:
Be careful not to scratch inner surface of casing.
4) Remove pressure switch.
D: INSPECTION
Perform the following inspection procedures and repair or
replace defective parts.
Part name Description Remedy
1. Front casing1) Damage on body surfaces
2) Excessive wear on hole, into which spool valve
is inserted.
3) Wear and damage on cartridge assembly mount-
ing surface
4) Wear and damage on surfaces in contact with
shaft and oil sealReplace with a new one together with spool valve
as selective fit is made.
2. Rear cover1) Damage on body surfaces
2) Wear and damage on sliding surfacesReplace with a new one.
3. Shaft1) Shaft bend
2) Wear and damage on surfaces in contact with
bushing and oil seal
3) Wear and damage on rotor mounting surfaces
4) Bearing damageReplace with a new one.
4. Side plate Wear and damage on sliding surfaces Replace with a new one.
5. Cam ring Ridge wear on sliding surfaces
If damage is serious, replace with a new cartridge
assembly. 6. Vane Excessive wear on nose radius and side surfaces
7. Rotor1) Wear and damage on sliding surfaces
2) Ridge wear on vane sliding grooves (If light
leaks with vane in slit against light source)
3) Damage resulting from snap ring removalCorrect with oil stone. If damage is serious, replace
with a new cartridge assembly.
8. Spool valve Damage or burrs on sliding surface peripheryReplace with a new one together with front casing
as selective fit is made.
9. Connector Damage on threads Replace with a new one.
10. Spring Damage Replace with a new one.
11. Bolts and nuts Damage on threads Replace with a new one.
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9. Oil Pump (Power Steering System)
Page 1184 of 2890

E: ASSEMBLY
1) Reassembly precautions
(1) Whenever O-rings, oil seals, and snap rings are
removed, they must be replaced with new ones.
(2) Thoroughly wash parts and allow to dry. They must
be kept free from cleaning oil and dust.
(3) Reassembly procedure must be performed in clean
place. Ensure that parts are kept away from waste
threads or other dust particles.
(4) Cleaning oil tends to stay inside the front casing.
Remove it completely by blowing compressed air.
(5) Ensure that parts are free from rust. (Use specified
hydraulic oil for rust prevention after cleaning and dry-
ing.)
(6) Reverse the sequence of disassembly procedures.
2) Shaft
(1) Apply grease to oil seal and inner surface of front
casing (at bearing location).
CAUTION:
Make sure that the front body internal surfaces are free
from damage.
G4M0184
(2) Using ST, press-fit oil seal into front body.
ST 340099AA000 INSTALLER
CAUTION:
When press-fitting, use care to prevent damage to sur-
face mating with rear body.
NOTE:
Orient oil seal toward correct direction.
G4M0185
(3) Using ST, press-fit shaft assembly into front body
and mount snap ring.
ST 340099AA020 INSTALLER
NOTE:
Turn snap ring to ensure that it fits right into the groove.
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4-3SERVICE PROCEDURE
9. Oil Pump (Power Steering System)