Power Steering Pump Service Procedure Modification (TS 5-10 04187)

Publication date: 1997-04-18
Reference number: TS 5-10 04187

POWER STEERING PUMP SERVICE PROCEDURE MODIFICATION

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 5-10 04187, Date of Issue: April 18, 1997

MODIFICATION OF POWER STEERING PUMP SERVICE PROCEDURES

Model(s): December, 1996 & 1997 Suzuki Sidekick & X-90 (Japan Built)

Section: Steering, Brakes & Suspension

Bulletin No.: TSB No. 5-10 04187

Date: April 18, 1997

CONDITION

Change in power steering pump service procedure.

CAUSE

Change in power steering pump (Japan built vehicles only).

CORRECTION

When servicing the power steering pump, please use the procedure as listed in this bulletin,

SERVICE INFORMATION

This bulletin is to inform you of the modification in the power steering pump and service procedures on the Japan built Sidekick and X-90 which have been carried out since December 1996 production. As a result of this change, the service procedures are different than those listed in the service manual. The Cami built vehicles remain unchanged.

Prior to servicing the power steering pump, be sure to identify the early style pump from the late style pump. If you have the EARLY style pump, follow the service procedures as listed in the service manual. If you have the LATE style pump, please follow the service procedures as listed in this bulletin. See Fig 1 .

ON-VEHICLE SERVICE

DISASSEMBLY PROCEDURE

See Fig 2 for Power Steering Pump components and location.

Clean off any dirt or grease from the exterior of the pump.
Carefully mount the pump into a vise with soft jaws to protect the pump housing.
Remove the suction connector bolt, suction connector and O-ring from the pump body.
Remove the power steering pressure switch (terminal set) from the pump body.
Remove the plug, flow control spring and relief valve (flow control valve) from the pump body.
Remove the cover bolts, pump cover and O-ring from the pump body.
Remove the snap ring from the pump shaft.
Remove the vanes from the rotor.
Remove the cam ring, rotor, side plate and O-rings from the pump body.
Remove the pulley from the pump body.
Remove the oil seal from the pump body.

INSPECTION

PUMP BODY, COVER, SIDE PLATE & SHAFT

Check the sliding surfaces of each part for deterioration and/or damage. If any defect is found, replace the pump assembly. See Fig 3 .

CAM RING

Check the vane sliding surface of the cam ring for wear and damage. If any defect is found, replace the pump assembly. See Fig 4 .

ROTOR & VANE

Check the sliding surfaces of the rotor and vane for wear and damage. See Fig 5 .
Check the clearance between the rotor and vane. See Fig 6 . Clearance: Standard 0.0004 in. (0.01 mm) Limit 0.0023 in. (0.06 mm)
If the clearance is out of specification, replace the pump.

RELIEF VALVE (FLOW CONTROL VALVE) & SPRING

Check the fluid passage and connector orifice for blockage or foreign material. See Fig 7 .
Check the sliding surface of the relief valve for wear and damage. See Fig 7 .
Check the free length of the relief valve spring. See Fig 8 . Free length: Standard 1.07 in. (27.2 mm) Limit 0.96 in. (24.2 mm)
If the free length is out of specification, replace the spring.

REASSEMBLY PROCEDURE

To reassemble the power steering pump; Reverse the disassembly procedure noting the following items: See Fig 9 .

Lubricate the oil seal lip with grease and the sliding surface of the shaft with power steering fluid.
Insert the pulley shaft through the oil seal and into the pump body. "A": Grease (P/N 99000-25010)
Apply power steering fluid to the O-rings and install them onto the pump body. See Fig 10 .
Install the side plate to the pump body.
NOTE: Carefully align the dowel pins on the side plate at 45° angle. See Fig 11 .
Apply power steering fluid to the siding surface of the rotor.
Install the rotor onto the shaft. See Fig 12 .
Install a new snap ring to the shaft, ensuring that it ts securely into the shaft groove. See Fig 12 .
NOTE: Never reuse the removed snap ring.
Apply power steering fluid to the sliding surface of the cam ring. See Fig 13 .
Install the cam ring to the pump body. Make sure the tapered end of the cam ring should face the slide plate. See Fig 13 .
Apply power steering fluid to each vane. See Fig 14 .
Install all ten vanes in the rotor. See Fig 14 .
Apply power steering fluid to the O-ring. See Fig 15 .
Install the O-ring to the pump body.
Apply power steering fluid to the sliding surface of the pump cover and rotor.
Align the dowel pins to the holes of the cover plate as shown and install the pump cover to the pump body. See Fig 16 .
Gradually tighten pump cover bolts to specified torque.
NOTE: After installing the pump cover, make sure that the shaft can be turned by hand. See Fig 17 . Tightening Torque: (a): 28 N.m (2.8 kg-m, 20.0 ft-lb)
Apply power steering fluid to the ring of the terminal set. See Fig 18 .
Install ring to the terminal set.
Install the terminal set to the pump body. Tightening Torque: (b): 28 N.m (2.8 kg-m, 20.0 ft-lb) See Fig 19 for plug, o-ring flow control spring and relief valve.
Apply power steering fluid to the relief valve (flow control valve).
Install the relief valve (flow control valve) into the pump body.
Install the flow control spring into the pump body.
Apply power steering fluid to the ring of plug.
Tighten the plug to the specified torque.
Apply power steering fluid to the O-ring of the suction connector. See Fig 20 .
Install the O-ring to the suction connector.
Install the suction connector to the pump body. See Fig 21 . Tighten the suction connector bolts to the specified torque. Tightening Torque: (d): 12 N.m (1.2 kg-m, 8.5 ft-lb)