Page 921 of 2453

PS-41
Oil Pump
POWER ASSISTED SYSTEM (POWER STEERING)
7. Oil Pump
A: REMOVAL
1) Disconnect the ground cable from the battery.
2) Remove the air intake duct.
7, REMOVAL, Air Intake Duct.>
3) Remove the pulley belt cover.
4) Remove the V-belts.
5) Disconnect the connector from power steering
pump switch.
6) Disconnect the pressure hose and suction hose
from power steering pump.
CAUTION:
•Do not spill power steering fluid.
•To prevent foreign matter from entering the
hose and pipe, cover the open ends with clean
cloth.
7) Remove the installation bolt of the power steer-
ing pump bracket.
8) Place the oil pump bracket in a vise, and remove
the two bolts from the front side of the oil pump.
CAUTION:
When securing the oil pump bracket in a vice,
hold the oil pump bracket with the least possi-
ble force between two pieces of wood.
9) Remove the bolt from the rear side of oil pump.
10) Disassemble the oil pump and bracket by in-
serting a flat tip screwdriver as shown in the figure.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Replace the fluid and perform air purge.
Tightening torque:
eral Description.>
CAUTION:
Never start the engine before filling with fluid,
as doing so may cause the vane pump to seize.
(1) Suction hose
(2) Pressure hose
PS-00736
(1)
(2)
PS-00741
PS-00742
PS-00743
PS-00129
Page 922 of 2453

PS-42
Oil Pump
POWER ASSISTED SYSTEM (POWER STEERING)
C: DISASSEMBLY
1) Using the ST, place the oil pump in the vise, and
remove the 4 bolts holding the rear cover.
ST 34199AE020 MOUNT
2) Remove the pressure plate.
3) Use a screw driver to pry the retaining ring.
CAUTION:
Do not remove the cam rings and rotors.
4) Install the pressure plate.
5) Temporarily tighten the rear cover to the front
casing.
6) Remove the oil pump pulley.
7) Place the oil pump in the vice.
CAUTION:
Do not place the oil pump in the vise directly.
Support the oil pump lightly using soft pads to
protect it.
8) Use a screw driver to pry the oil seal out.
CAUTION:
Be careful not to scratch the inner surface of
the casing.
D: ASSEMBLY
1) Caution during reassembly
(1) When removing O–rings, oil seals and snap
rings, always replace with new parts.
(2) Thoroughly wash the parts and allow to dry.
Make sure the parts do not come into contact
with cleaning oil or dust.
(3) The reassembly must be performed in a
clean place. Make sure lint or other foreign ob-
jects do not stick to parts.
(4) Cleaning oil tends to remain inside the front
casing. Use compressed air to completely clean
out any remaining cleaning oil.
(5) Make sure the parts are not rusted. Once
the parts are washed and dried, use a specified
hydraulic oil to prevent rust.
(6) Reassemble in the reverse order of removal.
2) At the bearing positions, apply grease to the oil
seal and front casing inner surfaces.
CAUTION:
Make sure the inner surface of the front body is
not damaged.
PS-00233
ST
PS-00234
PS-00235
PS-00236
PS-00237
Page 923 of 2453

PS-43
Oil Pump
POWER ASSISTED SYSTEM (POWER STEERING)
3) Temporarily tighten the rear cover to the front
body.
4) Attach ST to the front body. Using the press, in-
stall the oil seal.
ST 34199AE030 INSTALLER
5) Install the pump pulley to front body.
6) Using the ST, place the oil pump in a vise.
ST 34199AE020 MOUNT
7) Remove the rear cover.
8) Using a 10 mm box wrench, tap the retaining
ring into the shaft groove.
9) Install the pressure plate as shown in the figure.
10) Apply the specified hydraulic oil to the O-rings,
and attach to the front casing and pressure plate.
11) Install the seal ring to the pressure plate.
12) With knock pin positions aligned, install the rear
cover.
Tightening torque:
27.5 N·m (2.8 kgf-m, 20.3 ft-lb)
CAUTION:
Temporarily tighten the bolts in the order of (A),
(B), (C), (D) as shown in the figure. Then, tight-
en in the same sequence.
13) When reassembly is complete, turn the shaft by
hand to make sure that rotation is smooth. If it is ex-
cessively tight or there is a clear problem, detach
and check for foreign objects on the slide surface,
or whether there is any problems in the attachment,
and remove the cause of the problem.
(1) Groove
PS-00238
ST
PS-00239
PS-00240
( 1 )
PS-00241
( A )
( B )
( C )
( D )
Page 924 of 2453

PS-44
Oil Pump
POWER ASSISTED SYSTEM (POWER STEERING)
E: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and replace faulty parts.
2. SERVICE LIMIT
Make a measurements as follows. If it exceeds the
service limit, replace with a new one.
CAUTION:
•When securing the oil pump on a vise, hold
the oil pump with the least possible force be-
tween two pieces of wood.
•Do not set the outside of flow control valve or
pulley on a vise; otherwise outside or pulley
might be deformed. Select properly sized wood
pieces.
1) Play of the pulley shaft
Condition:
P: When applying the force of 9.8 N (1.0 kgf,
2.2 lb)
Service limit:
Play in the radial direction (Direction )
Less than 0.2 mm (0.008 in)
Axial play (Direction )
Less than 0.6 mm (0.024 in)
2) Deflection of the pulley groove
Service limit:
Less than 1.0 mm (0.039 in)
NOTE:
Read the value for one surface of V ditch, and then
the value for another off the dial.
No. Parts Inspection Corrective action
1Oil pump
(Exterior)
(1) Crack, damage or oil leakage Replace the oil pump with a new one.
(2) Play of pulley shaft
Measure the radial play and axial play.
If any of these exceeds the service limit, replace the oil pump
with a new one.
2Pulley
(1) Damage Replace with a new part.
(2) BendMeasure the V groove deflection.
If it exceeds the service limit, replace the pulley with a new one.
3Oil pump
(Interior)
(1) Faulty or seized of vane pumpCheck the rotating resistance of pulley.
If it exceeds the service limit, replace the oil pump with new one.
(2) Bend in the shaft or damage
to bearing
If the a string is wrapped on the pulley and rotated, and the oil
pump emits a noise that is markedly different in tone and loud-
ness from a sound of a new oil pump, replace the oil pump with
a new one.
4O–ring Cracking or deterioration Replace with a new part.
5Bracket Cracking Replace with a new part.
(1) Dial gauge
PS-00145P
(1)
(1) Dial gauge
(1) Dial gauge
PS-00146P
(1)
PS-00147
Page 925 of 2453

PS-45
Oil Pump
POWER ASSISTED SYSTEM (POWER STEERING)
3) Rotating resistance of pulley
Service limit:
Maximum load: 9.22 N (0.94 kgf, 2.07 lb) or
less
NOTE:
•A rather higher value may be indicated when pul-
ley starts turning.
•Measure the load during rotation to make a judg-
ment.
3. HYDRAULIC PRESSURE
NOTE:
•To measure hydraulic pressure correctly, be sure
to complete all the items in “INSPECTION”, prior to
performing the measurement.
SPECTION, General Diagnostic Table.>
•Do not leave the valve of pressure gauge closed
or hold the steering wheel at lock for 5 seconds or
more in any case, this can damage the oil pump.
•Before attaching a pressure gauge, place a
wastecloth at locations where fluid can be expected
to spill. Wipe off any spilt fluid completely after the
measurement.
1) Regular pressure measurement
(1) Connect the ST1, ST2 and ST3.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
(2) Remove the air intake duct.
(3) Disconnect the pipe C from pump.
(4) Using the gasket (Part No. 34621AC021)
and bolt (Part No. 34620AC010), install the ST2
to pump instead of pressure hose.
(5) Install the ST3 to the end of pressure hose
which is removed from pump.
(6) Replenish power steering fluid up to the
specified level.
(7) Open the valve, and start the engine.
(8) Measure the regular pressure.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
Service limit:
981 kPa (10 kg/cm2, 142 psi) or less
(9) If it is not within the specification, replace the
problem part for the following problems. (Pipe
or hose clogged, leaks from fluid line, and mix-
ture of foreign matter in fluid line)
(1) Spring balance
PS-00148
(1) Suction hose
(2) Pressure hose
(1) Valve
PS-00736
(1)
(2)
PS-00152
Page 926 of 2453

PS-46
Oil Pump
POWER ASSISTED SYSTEM (POWER STEERING)
2) Measure the relief pressure.
(1) Using the STs, measure the relief pressure.
(2) Close the valve.
(3) Measure the relief pressure.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
Service limit:
8,800 — 9,400 kPa (90 — 96 kg/cm2, 1,276 —
1,363 psi)
(4) If it is not within the specification, replace the
oil pump.
3) Measure the working pressure.
(1) Using the ST, measure the working pres-
sure.
(2) Open the valve.
(3) Measure the working pressure of control
valve by turning steering wheel from stop to
stop.
NOTE:
Because of the power steering system setup, there
are conditions where the pressure will not rise to
the repair limit value even if the steering wheel is
turned to the maximum steering angle. In this case,
turn the steering wheel further than the maximum
steering angle to measure the operational pres-
sure.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
Service limit:
8,800 — 9,400 kPa (90 — 96 kg/cm2, 1,276 —
1,363 psi)
(4) If it is out of specification, measure the steer-
ing effort.
STEERING EFFORT, INSPECTION, General
Diagnostic Table.> If it is not within specifica-
tion, replace the control valve itself or control
valve and pinion as a single unit, using new
parts.
(1) Valve
PS-00153
(1) Valve
PS-00152
Page 927 of 2453
PS-47
Reservoir Tank
POWER ASSISTED SYSTEM (POWER STEERING)
8. Reservoir Tank
A: REMOVAL
1) Drain fluid from the reservoir tank.
2) Disconnect the hose from reservoir tank.
CAUTION:
To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with clean cloth.
3) Remove the bolt and remove the reservoir tank
from the body.
CAUTION:
Do not separate the reserve tank and bracket.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Replenish power steering fluid up to the speci-
fied level.
Tightening torque:
33 N·m (3.37 kgf-m, 24.3 ft-lb)
C: INSPECTION
Check the reservoir tank for cracks, breakage or
damage. If a failure is found, replace the reservoir
tank.
(1) Reservoir tank
(2) Suction hose
(3) Return hose
PS-00744(3)
(2)
(1)
Page 928 of 2453

PS-48
Power Steering Fluid
POWER ASSISTED SYSTEM (POWER STEERING)
9. Power Steering Fluid
A: SPECIFICATION
B: INSPECTION
1) Check the power steering fluid for deterioration
or contamination. If the fluid is highly deteriorated
or contaminated, drain it and refill with new fluid.
2) Check the joints and units for oil leakage. If any
oil leaks are found, repair or replace the applicable
part.
3) Inspect the fluid level of reservoir tank with vehi-
cle on level surface and engine stopped.
If the level is at “MIN. ” point or below, add fluid to
keep the level in the specified range of the indica-
tor. If at “MAX. ” point or above, drain fluid by using
a syringe or the like.
(1) Check at power steering fluid temperature
20°C (68°F); read the fluid level on the “COLD”
side.
(2) Check at power steering fluid temperature
80°C (176°F); read the fluid level on the “HOT”
side.
C: REPLACEMENT
1) Lift-up the vehicle.
2) Remove the crossmember support.
3) Remove the pipe joint in the center of gearbox,
and connect the vinyl hose to the pipe and joint.
Wipe fluid off while turning the steering wheel.
4) Add the specified fluid to reservoir tank at “MAX”
level.
5) Continue to turn the steering wheel slowly from
lock to lock until the bubbles stop appearing on oil
surface while keeping the fluid at the level in the
Step 4).
6) If the steering wheel is turned in a low fluid level
condition, air will be sucked into the pipe. If sucked,
leave it about half an hour and then do the step 5)
again.
7) Start the engine and let it idle.
8) Continue to turn the steering wheel slowly from
lock to lock again until the bubbles stop appearing
on oil surface while keeping the fluid at the level in
Step 4).
Normally bubbles will stop appearing after turning
the steering wheel from lock to lock three times.
9) In case bubbles do not stop appearing in the
tank, leave it about half an hour and then do the
step 4) all over again.
10) Lower the vehicle, and then idle the engine.
11) Continue to turn the steering wheel from lock to
lock until the bubbles stop appearing and change of
the fluid level is within 3 mm (0.12 in).
12) In case the following happens, leave it about
half an hour and then do step 8) to 11) again.
(1) The fluid level changes over 3 mm (0.12 in).
(2) Bubbles remain on the upper surface of the
fluid.
(3) Grinding noise is generated from oil pump.
13) Check the fluid leakage after turning steering
wheel from lock to lock with engine running.
Recommended power steering fluid Manufacturer
AT F D E X R O N I I I o r e q u i v a l e n t
B.P.
CALTEX
CASTROL
MOBIL
SHELL
TEXACO
PS-00745
HOT MAXHOT MAINCOLD MAXCOLD MAIN