P/S Pump Disassembly and Assembly: Assembly

1. Apply grease to oil seal (1) lip and apply power steering fluid to sliding surface of the shaft (2) then insert pulley's shaft (2) from oil seal side of the pump body.
   Fig 1: Inserting Pulley Shaft From Oil Seal Side Of Pump Body

   Courtesy of SUZUKI OF AMERICA CORP.
2. Apply power steering fluid to O-rings (1) and fit them to pump body.
   Fig 2: Identifying O-Ring

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3. Install side plate (1) to pump body.
   NOTE: Carefully align the dowel pins on the side plate (1) at bolt hole (2) as shown in the figure.
   Fig 3: Installing Side Plate To Pump Body

   Courtesy of SUZUKI OF AMERICA CORP.
4. Apply power steering fluid to sliding surface of rotor (1)
5. Install rotor (1) 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 into shaft groove securely.
   NOTE: Never reuse the removed snap ring (2).
   Fig 4: Installing Snap Ring To Shaft

   Courtesy of SUZUKI OF AMERICA CORP.
7. Apply power steering fluid to sliding surface of cam ring (1).
8. Install cam ring (1) 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 (2) (10 pieces) 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 To Pump Body

    Courtesy of SUZUKI OF AMERICA CORP.
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 Dowel Pins To Holes Of Cover Plate

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

Tightening torque 

P/S pump cover bolt (a): 23 N.m (2.3 kg-m, 17.0 lb-ft) 

Fig 9: Tightening P/S Pump Cover Bolt
Courtesy of SUZUKI OF AMERICA CORP.
16. Apply power steering fluid to O-ring of pressure switch.
17. Install pressure switch (1) to pump body.

Tightening torque 

Pressure switch (a): 28 N.m (2.8 kg-m, 20.5 lb-ft) 

Fig 10: Installing Pressure Switch To Pump Body
Courtesy of SUZUKI OF AMERICA CORP.
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 to specified torque.

    Tightening torque 

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

Fig 11: Tightening Plug To Specified Torque
Courtesy of SUZUKI OF AMERICA CORP.
24. Apply power steering fluid to O-ring (2) of suction connector (1).
25. Install O-ring (2) to suction connector (1).
    Fig 12: Installing O-Ring To Suction Connector

    Courtesy of SUZUKI OF AMERICA CORP.
26. Install suction connector (1) to pump body as shown in the figure.

Tighten suction connector (1) bolts to specified torque.

Tightening torque 

Suction connector bolt (a): 10 N.m (1.0 kg-m, 7.5 lb-ft) 

Fig 13: Installing Suction Connector To Pump Body

Courtesy of SUZUKI OF AMERICA CORP.