P/S Pump Disassembly and Assembly: Assembly

Reference: P/S PUMP INSPECTION 

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.

   "A": Grease 99000-25010SUZUKI Super Grease A 

   Fig 1: Identifying Oil Seal, Pulley Shaft & Grease Application Area

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2. Apply power steering fluid to O-rings (1) and fit them to pump body.
   Fig 2: Identifying 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) at bolt hole (2) as shown in figure.
   Fig 3: Identifying Side Plate & Bolt Hole

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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: Identifying Snap Ring, Rotor & Dot

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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: Identifying Cam Ring & Side Plate

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

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11. Apply power steering fluid to O-ring (1).
12. Install O-ring (1) to pump body.
    Fig 7: Identifying 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: Identifying Dowel Pins & 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: Identifying P/S Pump Cover & Bolts

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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: Identifying Pressure Switch

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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: Identifying Plug

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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

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26. Install suction connector (1) to pump body as shown in 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: Identifying Suction Connector & Bolts

    Courtesy of SUZUKI OF AMERICA CORP.