P/S Pump Disassembly and Assembly: Assembly

Reverse disassembly procedure for assembly, noting the following.

1. Apply grease to oil seal lip (1). Apply power steering fluid to sliding surface of the shaft (2) and then insert shaft in the pump body.

   "A": Grease 99000-25010 

   Fig 1: Applying Grease To Oil Seal Lip And Power Steering Fluid To Sliding Surface Of The Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
2. Apply power steering fluid to O-rings (1) and fit them to pump body.
   Fig 2: Applying Power Steering Fluid To O-Rings

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3. Install side plate (1) to pump body.
   NOTE: Carefully align the dowel pins on the side plate (1) with the bolt hole (2) as shown in the figure.
   Fig 3: Aligning The Side Plate With Bolt Hole

   Courtesy of SUZUKI OF AMERICA CORP.
4. Apply power steering fluid to sliding surface of rotor (1).
5. Install rotor to shaft, directing dot (3) marked side of rotor facing up.
6. Install new snap ring (2) to shaft, then make sure to fit snap ring into shaft groove securely.
   NOTE: Never reuse the removed snap ring.
   Fig 4: Installing Rotor To Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
7. Apply power steering fluid to sliding surface of cam ring (1).
8. Install cam ring to pump body. The tapered end of cam ring (1) should face the side plate (2).
   Fig 5: Installing Cam Ring To Pump Body

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9. Apply power steering fluid to each vane (2).
10. Install vanes (12 pieces) (2) to rotor (1).
    Fig 6: Installing Vanes To Rotor

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11. Apply power steering fluid to O-ring (1).
12. Install O-ring (1) to pump body.
    Fig 7: Installing O-Ring

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13. Apply power steering fluid to sliding surface of pump cover and rotor.
14. Match the dowel pins (1) to the holes of the cover plate (2) as shown and install pump cover to pump body.
    Fig 8: Matching The Dowel Pins To The Holes

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15. Gradually tighten pump cover bolts to specified torque.
    NOTE: After installing pump cover (1), check to make sure that shaft can be turned by hand.

    Fig 9: Tightening Pump Cover Bolts

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    Tightening torque 

    Pump cover bolt (a): 28 N.m (2.8 kg.m, 20.0 lb-ft)

16. Apply power steering fluid to O-ring of terminal switch.
17. Install pressure switch (1) to pump body.
    Fig 10: Installing Pressure Switch

    Courtesy of SUZUKI OF AMERICA CORP.

    Tightening torque 

    Pressure switch (b): 28 N.m (2.8 kg.m, 20.0 lb-ft)

18. Apply power steering fluid to relief valve (flow control valve).
19. Install relief valve (flow control valve) to pump body.
20. Install flow control spring.
21. Apply power steering fluid to O-rings of plug.
22. Install O-rings to plug.
23. Tighten plug (1) to specified torque.
    Fig 11: Tightening Plug

    Courtesy of SUZUKI OF AMERICA CORP.

    Tightening torque 

    Plug (c): 60 N.m (6.0 kg.m, 43.5 lb-ft)

24. Apply power steering fluid to O-ring (2), and install O-ring to suction connector (1).
    Fig 12: Installing O-Ring To Suction Connector

    Courtesy of SUZUKI OF AMERICA CORP.
25. Install suction connector (1) to pump body as shown in figure. Tighten suction connector bolt to specified torque.

    Tightening torque 

    Suction connector bolt (d): 12 N.m (1.2 kg.m, 8.5 lb-ft)

    Fig 13: Installing Suction Connector

    Courtesy of SUZUKI OF AMERICA CORP.